Over a period of over 20 years in the GRP roofing and architectural elements industry, there have been many advancements in the manufacturing process and the use of GRP in the construction industry.
An abbreviation for ‘glass reinforced polyester’, GRP is a lightweight, durable and surprisingly strong building material that can be molded and manufactured into all types of products. GRP is a composite of a strong and durable resin with an immensely strong fibrous glass. Polyester resin is the main component and just like concrete can be reinforced with steel rods, polyester resins can be reinforced with glass fibers to form GRP. The benefits of a very strong and lightweight building material are particularly relevant when designing and manufacturing roof structures and features.
GRP has opened many new avenues for creative architects and designers, its unique physical properties allow it to be easily worked, molded and fabricated to meet almost any specification. The final finish can emulate any number of natural surfaces, such as wood, tile, stone or lead and because there are few limitations on size, shape, color or finish, this can offer a great design and appearance while being cost effective. . .
An example of this is the traditional clock tower. When manufactured in GRP, one face is first made by hand in ash wood from which a mold tool is produced. The mold is coated with a mold release agent prior to applying a highly durable polyester gel coat and allowed to cure before reinforcing with layers of polyester resin impregnated glass mat to achieve the required thickness. Once cured, the laminate is removed from the mold and then the process is repeated. The components are then put together to complete the body of the clock tower.
Ash wood is used for the original pattern to ensure that the finished product has a beautiful realistic wood grain. Similarly, one side of a roof is first lead-lined over a wood pattern, a mold is produced, and four sides are fabricated to give the finished product an authentic traditional appearance of a genuine lead roof, but without the high cost. and weight of actual materials. Another benefit of using GRP over traditional materials is that the molds can be cleaned and reused many times, allowing identical units to be produced in a very short space of time.
GRP is also very strong and has almost seven times the flexible strength of steel, but it is extremely lightweight, making installation much simpler than its traditional material counterparts, saving costs and helping to reduce health problems and site security. GRP structures also have an extremely long service life with low maintenance requirements and in half a century of composite development, well-designed GRP structures have yet to wear out.
GRP is non-corrosive and has a much longer life expectancy compared to a variety of other building materials. In highly corrosive environments, it is the perfect choice on metal, wood or plastic. A popular choice where exposure to harsh environments is a concern, GRP can provide resistance to UV light, salty air and a variety of chemicals and, because it is chemically inert and resistant to corrosion, offers an economical alternative. to stainless steel. It also offers high levels of water resistance and will not bend or warp in high temperatures.
An astonishing level of detail can be given to the trim ensuring that the original style, surface finishes, color and even aging effects are maintained. However, the greatest advantage of GRP over conventional materials is the ability to design and build large structures conceived as a whole and not as a set of pieces that must be joined together. For example, a 5m diameter dome does not require any conventional support structure within the building, allowing for a large open area within the building and a space directly below the dome. The self-supporting structure can also be easily lifted into position and installed with minimal labor and a crane in just a few hours.
Therefore, GRP not only saves time and money on roof feature construction, but also reduces installation costs and ongoing maintenance fees, making it a great cost-effective roofing material for today and the future.