GFRC Compaction Rollers

Product Detail:

Compaction Rollers for spreading out and flattening GFRC.

Aluminum construction for unbeatable durability and performance.

Use to roll over GFRC to compact the mix, and remove any excess air pockets.

Using Compaction Rollers will strengthen the GFRC piece, by helping to ensure density.

Types of Rollers:

• Bubble Buster: Best at relieving air pockets, easy to clean.
  
• Corner Roller: Use to get into tight areas and corners.
  
• Radius Rollers: Curved roller for getting into concave surfaces.

Product Specifications:

Stocked Roller Sizes:

• 1/2" Diameter x 3" Wide, Bubble Buster Roller (aluminum).
  
• 1/2" Diameter x 6" Wide, Bubble Buster Roller (aluminum).
  
• 1" Diameter x 9" Wide, Bubble Buster Roller (aluminum).
  
• 1/4" Radius Corner Roller (aluminum).
  

Shipping Information:

Usually ships within 1-2 business days.

Sample Photos:











GFRC Basics:

GFRC (Glass Fiber Reinforced Concrete) is lighter, stronger, faster, and cheaper than most typical concrete mixes.

GFRC pieces can be de-molded after 24 hours.

A Typical GFRC mix 1:1 ratio means One 90 lb. sack of cement and One 100 lb. bag of sand.

For many countertop type applications, smaller batches are sufficient, such as 1/4 this amount.

The Expressions-LTD Basic GFRC Mix below works great for GFRC countertops, sinks, and furniture pieces.

Expressions-LTD Basic GFRC Mix:

Equipment Needed: 5 Gallon Bucket. Heavy Duty Electric Mixer and Paddle Mixing Blade. Scale. Measuring Cup. Hopper Sprayer and Air Compressor. Compaction Roller(s).

• FACE COAT:
  
• Add 6.5 lbs. water (about 3 quarts) to a clean 5 gallon bucket.
• Add 2.5 lbs. of Polyplex Curing Aid.
  
• Add 1 Fl. Ounce of SP 7000 Super Plasticizer.
  
• Mix in 23.5 lbs. of #30 Silica Sand (#30 is the sand size, and available at your local hardware store).
  
• Mix in 17.5 lbs. Portland Cement (white or gray, available at your local hardware store)
  
• Mix in 6 lbs. Vitro Minerals Pozzolans (VCAS).
  
  
• Optional: Mix in any Integral Color, if desired.
  
• Add extra water if needed, in small amounts, until mix is creamy.
  
• Let mix 'set' (usually about 5 minutes) and then remix briefly.
  
• Spray Face Coat of this mix over the mold/form work using a Hopper Sprayer such as the MK3 GFRC Sprayer. Face coat should be 1/8" - 3/16" thick.
• Allow face coat to sit long enough to stiffen, but remain moist (Time varies, usually 30-45 minutes).
  

• BACKER LAYERS:
  
• Mix another batch, same formula as above.
  
• Slowly mix in 1.6 lbs. of 3/4" Length AR Glass Fibers.
  
  
• Hand lay the fiber-rich backer layer mix over the surface of the mold/form at a 3/8" - 1/2" thickness.
  
• Use Compaction Rollers to even out this layer, condense, and remove any air pockets.
  
• Place a second backer layer, again 3/8" - 1/2" thickness, and compact with rollers.
  
• Finished piece should be 3/4" - 1" thick at a minimum.
  
• Additional layers can be added, or a slightly wetter mix can be used last to 'top off' the mold form, and level out the concrete.
  

• EXTRA REINFORCING:
  
• Extra Reinforcing: Fiberglass Scrim Fabric can be placed between GFRC Backer layers.
  
• Fiberglass Scrim will help increase overall strength and flexibility. Ideal for reinforcing around integral concrete sinks.
  
• Try to keep Scrim 1/2" away from the Face Coat, to avoid ghosting (faint lines showing an image of something buried in the concrete).
  
  
• A second layer of Scrim can be laid down over the final coat of GFRC, and lightly rolled down into the cement surface.
  

• COVERAGE, WEIGHT, and COSTS:
  
• Face Coat Batch: Covers approx. 80 sq. ft. at 1/8" thickness.
  
• Backer Layer Batch: Covers approx. 30 sq. ft. at 3/8" thickness.
  
• Finished GFRC Piece Weight: At 3/4" thickness: 8 lbs per sq. ft. At 1" thickness: 10.5 lbs per sq. ft.
  
• Material Cost Approximates: At 3/4" thickness: @$1.99 per sq. ft. At 1" thickness: @$2.65 per sq. ft.
  

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