Jul. 07, 2025
GFRC, or Glass Fiber Reinforced Concrete, is a versatile, high-performance concrete mix that incorporates alkali-resistant glass fibers to produce a material with exceptional strength and reduced weight. Widely used in architectural applications such as building cladding, GFRC concrete is an ideal choice for countertops, wall panels, and custom concrete surfaces.
By combining concrete with glass fibers, GFRC offers unique benefits over traditional concrete, from added durability to design flexibility.
This innovative material can be applied in a variety of ways to suit different project needs:
By utilizing these methods, GFRC provides unmatched versatility, making it a top choice for modern construction and design projects.
Here are some standout benefits of the preferred choice for projects requiring lightweight yet robust materials:
GFRC concrete can be molded into a variety of shapes, textures, and finishes, allowing designers and fabricators to create unique surfaces that align with aesthetic goals without sacrificing durability.
Compared to traditional concrete, GFRC is up to 75% lighter. This makes GFRC concrete ideal for large, intricate designs where weight is a concern, such as countertops, sculptures, and architectural panels.
GFRC withstands environmental stress, including moisture, temperature changes, and UV exposure, making it an ideal option for indoor and outdoor applications alike.
The glass fibers embedded in GFRC create a durable matrix that provides superior flexural and tensile strength, reducing the likelihood of cracks and breakage over time.
GFRC was developed for architectural concrete and manufacturing architectural products such as: wall panels, window surrounds, column covers, soffits, cornices, brackets, quoins, railings, pilasters, copings, domes, site furnishings, planters, bollards, urns and tables. In recent decades, it has become the material of choice for creative concrete applications such as countertops, furniture, sinks, fire pits, fireplace surrounds, decorative wall panels and more.
Just like regular concrete, GFRC can accommodate a variety of artistic embellishments including acid staining, dying, integral pigmentation, decorative aggregates, veining and more. It can also be etched, polished, sandblasted and stenciled. If you can imagine it, you can do it, making GFRC a great option for creating concrete countertops and especially three-dimensional concrete elements.
Here are just a few of the amazing applications of GFRC in the realm of creative concrete:
Understanding the ingredients in GFRC is essential for creating a high-quality final product. A typical GFRC mix includes the following components:
A well-balanced mix includes Portland cement and fine sand, often at a 1:1 ratio, to ensure a smooth texture. Fine sand (#50-#30 sieve) is ideal for consistency and surface finish. Click here for more information about the best sand for GFRC.
Add polymers to enhance flexibility and reduce shrinkage. Acrylic polymers are especially beneficial as they offer UV stability, resist yellowing, and provide excellent bonding properties. Click here for more information about polymer.
Use alkali-resistant glass fibers to reinforce the concrete matrix, making it stronger and more resilient to cracking and environmental wear. These fibers are crucial for maintaining the structural integrity of GFRC. Click here for more information about AR glass fibers.
The workability of the GFRC mix can be adjusted with the addition of water reducers. These agents help modify the consistency of the mix, making it suitable for various applications without sacrificing its integrity. By incorporating a series of water reducers, you can achieve the desired workability while maintaining the essential properties of the mix.
As with all concrete, measure water precisely, maintaining a low w/c ratio of 0.30 to 0.35. Use superplasticizers to improve flowability without compromising strength, helping create thin sections and complex shapes with ease. Click here for more information about superplasticizers in concrete countertop mixes.
Combining these methods allows for greater control over the mix’s workability, ensuring that your GFRC projects meet both aesthetic and structural requirements.
You may include pozzolans (such as silica fume, metakaolin or VCAS) as cement replacements. Click here for more information about the use of pozzolans in concrete countertop mix design.
Calculating the actual GFRC mix proportions can be complex, involving intricate mathematical calculations. If you would like more detail about these calculations, please see this article. See also this powerful and versatile GFRC mix calculator that does all of the calculations for you.
If you just want to get a mix that is already proportioned, you can purchase kits that include the mix, the fibers, and the superplasticizer you will need:
You can use these GFRC concrete countertop mix recipes with the Kits.
The production process involves unique premix or spray techniques to ensure even distribution of glass fibers, resulting in a high-quality, uniform finish.
Spray-Up GFRC is applied similarly to shotcrete, with the concrete mixture sprayed into the forms. The process uses a specialized spray gun with a fiber chopper to apply the fluid concrete mixture and to cut and spray long glass fibers from a continuous spool at the same time. Spray-up creates very strong GFRC due to the high fiber load, long fiber length and correct fiber orientation. However, the equipment can be very expensive ($20,000 or more).
If you’re considering whether the GFRC mix contains preblended fibers, it’s important to note that fibers are not preblended into the GFRC mix. This allows you the flexibility to select the fiber combination and load rate that best suits your project needs.
In the Premix method, glass fibers are mixed directly with the concrete. The fluid concrete mixture is then poured or sprayed into molds. This approach works well for smaller projects or pieces requiring thick layers of GFRC concrete. Premix is weaker than Spray-Up because the the fibers are shorter and placed more randomly throughout the mix.
A hybrid method for creating GFRC involves using a hopper gun to spray a thin, fiber-free face coat (mist coat) into the mold, followed by a hand-packed or poured backer mix with fibers.
This is an affordable way to get started, because the required hopper gun is inexpensive. However, it is critical to carefully create both the face mix and backer mix to ensure similar consistency and makeup. You must also know when to apply the backer coat so that it adheres properly to the thin mist coat but doesn’t tear it. Click here for a video about how to tell when the mist coat is ready for backer.
Most concrete countertop makers today use either a hybrid method or a premix method, which they often refer to as “direct cast”. The biggest risk with the direct casting method for GFRC is that fibers show in the finished surface of the countertop or element. This is mitigated by using specialized AR glass fibers specifically designed for concrete countertops, not for building panels.
Each of the Application Methods mentioned above can be used in conjunction with one or more of these production processes:
The high polymer content of GFRC means that long term moist curing is unnecessary. Cover a freshly cast piece with plastic overnight. This could be shorter if it has gained enough strength to be uncovered and processed. Many pieces are stripped 16 to 24 hours after casting.
Your skill level, the composition of your mix and the method used will determine how much processing is needed once your GFRC countertop is removed from its molds. Grouting may be needed to fill in bug holes or surface imperfections. Any blowback (sand and concrete that doesn’t stick to the forms) needs to be cleaned or the concrete’s surface will be open and granular. Achieving a perfect piece right out of the mold requires skill and practice.
Typical concrete countertops made with GFRC range from ¾” to 1” in thickness. This is the minimum thickness that a long, flat countertop can be made so it doesn’t break when handled or transported. Smaller wall tiles can be much thinner.
For other applications, this mix is typically made at 0.75” – 1” thick. However, when casting objects like tiles, the mix is often cast at ½” thick. This thinner casting requires careful consideration in the handling and support of the piece to prevent damage.
By understanding these thickness variations, you can choose the right GFRC application for your project needs, ensuring both durability and aesthetic appeal.
GFRC is lighter, thinner, and stronger than traditional precast concrete countertops, enabling larger, seamless designs with reduced labor and faster turnaround times. See this article “10 Reasons Why GFRC is Better than Precast for Concrete Countertops” for details.
GFRC is roughly on par with other forms of concrete countertops in terms of the “green-ness” or being environmentally friendly. In comparing 1.5” thick concrete countertops to ¾” GFRC countertops, the same amount of cement is used. This is because GFRC tends to use about twice as much cement as ordinary concrete. The use of polymers does make GFRC less green than using ordinary water, which could be recycled from shop use. Both traditional cast and GFRC can use recycled aggregates. Steel reinforcing is more green than AR glass fibers, since steel is the most recycled material. Therefore steel’s use in concrete of any form boosts the concrete’s green-ness.
The final color of GFRC depends on the ingredients. If you use white sand and white cement in the GFRC mix, it will naturally cure to a bone white color. You can boost the whiteness by adding white pigments.
Yes, GFRC mix can indeed be pigmented. You have the flexibility to tint it using a variety of color collections available on the market. Many manufacturers offer diverse ranges of pigments specifically designed for concrete mixes. These color options allow you to achieve customized hues that cater to your specific aesthetic needs.
Absolutely, you can add decorative aggregates to the GFRC (Glass Fiber Reinforced Concrete) mix. This customization is quite popular for those looking to enhance the visual appeal of their projects.
The standard GFRC mix typically doesn’t include larger aggregates. This allows you the flexibility to incorporate decorative options such as colored stones, glass bits, or various custom aggregates to create unique textures and appearances. By starting with this base, you have the freedom to craft your own specific mix, tailored entirely to suit your design vision.
If you’re aiming for a one-of-a-kind project, consider these steps:
In short, GFRC mix’s versatility makes it an excellent choice for bespoke designs, enabling you to fully express your creativity with decorative aggregates.
Any product that can be used with concrete can be used with GFRC. This includes pigments, decorative aggregates, pozzolans, water reducers and even PVA fibers. GFRC is concrete, after all.
For from-scratch ingredients, GFRC tends to cost about $2.50-$3.00 per square foot for ¾” thick material. The cost increases to about $3.50-$3.75 per square foot for 1” thick material when accounting for the prices of sand, cement, admixtures, fibers and polymer. The cost of pre-blended mix may be higher.
Here are some interesting facts about GFRC: GFRC was first created in the s in Russia. It wasn’t until the ’s that the current form came into widespread use for building façades, largely due to the introduction of curing polymer that made 7-day wet curing unnecessary.
If you want to learn more, please visit our website Jushui.
Join us for hands-on training designed for professionals who want to use GFRC to create countertops, sinks, furniture, fire pits and more.
We also offer 2-hour online video training “Professional GFRC for Concrete Countertops and More”. Watching an actual GFRC countertop being constructed will help you better understand many of the topics covered in this article.
Check out the 7 minute excerpt below. See what you can learn from Jeff in only 7 minutes – and imagine what you can learn in 2 hours! Click here to learn A LOT more in “Professional GFRC for Concrete Countertops and More”.
View our FREE, 2.5 hour seminar “Step by Step GFRC with Mix Design” by requesting access here.
Concrete transcends most materials. This liquid-to-solid stone allows complete manipulation of shape and appearance. It’s no surprise that architects and designers are intrigued by concrete and have been utilizing it in their designs for centuries.
The appearance of each concrete product displays the process and the story with which it was cast, not unlike how our lives and experiences shape who we are. The manufacturing process creates a well-crafted and aesthetically pleasing product for those who appreciate and understand the true beauty of this material.
There are 10 specific things you really need to know as you consider adding this material to your project.
Modern, rustic, contemporary, traditional, transitional and industrial, concrete has unmatched versatility when it comes to shape, color and size.
While granite and marble surfaces are beautiful in their own way, they both exhibit a great deal of variation in color and pattern due to the level of impurities they contain. Features such as veins, color deposits, speckling and mottling are common in these materials, making them somewhat of a challenge to work with when it comes to coordinating against an overall design theme.
In contrast, concrete pieces contain very subtle variation. This is because they are designed with intent - all of the materials and pigments used are determined up front, measured out, and then cast and cured according to a specific process. In addition, the shape of the piece - and thus the degree of modernity or antiquity - can be designed into the mold prior to casting.
For these reasons, concrete tends to align with a multitude of color schemes, tile patterns, architectural styles - making it the ideal medium for timeless appeal.
The ubiquitous material poured into sidewalks and foundations is the crudest expression of concrete. But there is an endless spectrum of cement mixtures, some of which are quite applicable inside the home. When it comes to concrete site furnishings, the most common - and useful of these mixtures - is known as GFRC.
GFRC stands for glass-fiber-reinforced concrete. The glass fibers provide much higher tensile and flexural strength than standard structural concrete. GFRC typically has many high quality mix additives and a lower water-to-cement ratio. This enables it to easily reach a compression rating of 10,000 psi once cured (standard concrete has a compression rating between 2,500 psi for residential structures to 4,000 psi and higher in commercial structures).
These characteristics translate into real-world advantages. Because GFRC is so strong, fabricators can cast pieces that are larger, thinner, or otherwise not achievable when using standard concrete and other solid surfaces.
Lighter concrete enables fabricators to create very large and thin pieces - enormous tables, kitchen islands, countertops, wall panels, etc.
GFRC is lighter than traditional concrete for 2 main reasons: First, because it is stronger, it can be cast much thinner while retaining the same integrity. Less material means less weight. Second, its glass fibers are significantly lighter than the same volume of aggregate (heavier sand or aggregate) they are substituting. A 30” sink made of GFRC only weighs ~75 lbs and can be shipped throughout the world using UPS.
Additionally, in the case of longer objects (e.g. lengthy tables), GFRC’s strength makes it less dependent on use of steel reinforcement rods that might be required when using traditional cast concrete. GFRC is also 30% lighter than granite per square foot.
Overall, the utility of GFRC is an obvious choice for fabricators and end users alike as it reduces the weight burden on nearly every aspect of concrete furnishings including production, shipping and installation.
A truly hand-made product is made by people for people. It is one-of-a-kind, carrying the signature of having been created at a unique place in time while under a specific set of conditions. Every attribute of the finished product was determined, revealed, or finessed by a human being.
Casting concrete is extremely hands-on and labor intensive. Every project makes its way through each stage of the manufacturing process where it is met with the same high level of care from craftsmen wielding the necessary tools and the proper experience.
There is an intense amount of oversight and quality control that goes into making sure that every detail meets or exceeds both internal standards and the expectations of the client.
While inherently laborious, it means that each piece is monitored by multiple people on a continuing basis - from the moment it is cast to the point where it leaves the factory. Defects or problems can therefore be detected at a very early stage and then quickly addressed.
Just like a fine painting is coated in a final skin of varnish that pulls it altogether, concrete furnishings - particularly sink, tables and countertops - should be properly sealed.
But not all sealers are created equal. Naked concrete - even GFRC - is inherently porous and therefore must be sealed to protect it over time. Since there is no industry standard for sealing concrete, each fabricator has their own sealing processes and methods.
The two most common ways to seal concrete are with either Topical Sealers or Reactive Sealers. No sealer or sealing method is bulletproof and should not be expected to last a lifetime. There may be a point where the concrete seal will need to be reapplied or touched up to maintain a durable and beautiful finish.
Reparability is the most important trait for any sealer. Avoid inexpensive penetrating sealers and/or wax as neither of these give the concrete a great level of protection.
Because concrete is cast from liquid to solid, it provides an opportunity to create truly unique pieces containing features that will enhance the user’s experience and reflect his/her lifestyle. Sink drainboards, aprons/drop edges, trivets, surface elevation changes, etc. can all be incorporated into the project during the casting process.
Concrete countertops and sink basins cast as a single piece are referred to as Integrated Sinks. This process yields a seamless and easy-to-maintain finished product. Unlike the case with granite or quartz, there is no need for purchasing a separate undermount sink, cutting the appropriate countertop holes, and then attaching the sink.
In addition to being stronger than other alternatives, integrated sinks will be devoid of gaps that can trap water and other debris - making them easier to clean and thus more hygienic.
Rather than having mitered seams, furnishings like tables and kitchen island tops with “waterfall legs” can all be cast as one solid piece.
Concrete site furnishings can be customized in a wide variety of ways to suit the projects for which they're planned. The dimensions, color, ADA compliance and number of faucet holes are merely the most common forms of customization.
But concrete can also be personalized by utilizing many other creative treatments. Techniques applied to liquid concrete include stamping, casting onto unique surfaces or patterns, embedding objects or other materials (wood, stones, metallic powders, mosaic tiles, towel racks, etc.), and embossing (casting against objects that are later removed, leaving an impression).
Techniques can also be applied to the concrete once it has hardened. These include distressing (antiquing), etching (or removing concrete) via the use of acid, and further coloring and/or pigmentation.
It is common for companies to have their logos and brands distinguished and captured in concrete this way, or for designers to add unique images or messaging.
Concrete furnishings are handmade using a complex brew of materials in exacting quantities. Yet, even two identical sinks made on the same day by the same artisan with the same ingredients and formulation will have slightly different surface and edge characteristics. It is not unlike different grains of the same wood or pattern variations in granite, only more subtle.
The unique patina of each piece is largely due to the curing process through which the liquid product becomes a fused, high-strength solid product. But there are a multitude of factors that contribute to natural variation, including (but not limited to) cement particle size and moisture content, aggregate type and size, pigments (if applicable), the length of time spent mixing and pouring, the casting material (e.g. wood, melamine, steel, etc.), the method of compaction, ambient temperature and humidity, the type of post-cast finishing performed, the type of sealer used (if any), and the style and technique of the artisan crafting the piece.
In any finished concrete piece, surface variations are as much a key aesthetic feature as they are a signature of all that went into creating it.
Since most concrete pieces are made-to-order, it is important to adequately plan for manufacturing time, shipping, and preparation.
In terms of timing, keep in mind that handmade furnishings might take several weeks before they arrive at their final destination. Highly customized projects - either commercial or residential - might require more time due to additional engineering or higher degrees of detail or complexity.
Especially large or custom pieces can also present a different kind of challenge: will it even fit through the doorways, stairwells or elevators that stand between the truck and the ultimate destination?
Some concrete projects (e.g. sinks or wall panels) might require that brackets, bolts, reinforcements, or other mediums be mounted to studs, walls, floors, and other surfaces prior to installation. And while certain environments may present unique challenges, other environments might present opportunities.
Be sure to speak to the fabricator to ascertain whether there are any preparatory steps or sequences you must take in order to guarantee a successful installation.
Concrete is the single most utilized material in the history of civilization. That’s because so few materials are as simultaneously robust, long-lasting and versatile as concrete.
From DIYers fiddling in their garage, to state-of-the-art government laboratories attempting to crack the next civil engineering super material, there is an astonishing amount of global research and development aimed at making concrete even more relevant than it already is. The last decade alone has experienced a significant resurgence in interest for using concrete to create things ranging from jewelry to 3D-printed bridges.
It’s no surprise then that concrete has managed to shed its reputation as a vestige of over-urbanization and steadily migrate into the household in the form of innovative, refined, functional objects that both serve and inspire.
The only question remaining is “just how far can we take this material?”
As you can see, concrete design goes far beyond what you might have imagined. It is the medium of the imagination. It can go nearly anywhere and nearly do anything. Take a closer look at concrete for your home—inside and out.
If you are looking for more details, kindly visit GFRC Wall Panels.
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