working together

COMPANYPROFILE

CONTENTS

About Us.................................................... 2Our Services.................................................5Consultancy................................................ 7GRC DFMI................................................... 9Installation / Repairs.................................... 11Supply & Fit Solutions................................. 13Anchor Testing............................................15Stonework & Masonry Design..................... 17

WHATWEDO

We are a specialist GRC/GFRC company offering a range of services to architects, main contractors, façade contractors and manufacturers. Originally GRC Synergies was formed to provide support services to leading manufacturer Glass Reinforced Concrete UK (GRCUK). However with the sale of GRCUK to the Laing O’Rourke Group in early 2014 the Company became independent and now works in partnership with many leading GRC, cast stone and precast manufacturers.

All our leadership and senior management team have unrivalled experience in the industry putting us in a unique position to assist anyone involved in the manufacture or application of glass reinforced concrete.

Operating from offices in both the UK and China we have a global presence in the worldwide and rapidly expanding GRC/GFRC industry.

SYNERGY - the interaction of elements that when combined produce a total effect that is greater than the sum of the individual elements.“ ”

3

OUR SERVICES

Our services cover everything from concept to completion and include design, engineering, testing, installation and general consultancy. We are pioneering the design for manufacture and installation approach we think is essential to the GRC industry through our use of advanced 3D modelling software.

5

CONSULTANCY

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We understand every aspect of this remarkable composite and all the processes required to take architectural concepts through to completed projects. These include initial design concepts, product realization through design engineering, mould manufacture, Spray & Premix production, testing, logistics and finally installation on site.

With this unique collective knowledge our team can provide a range of consultancy services to both manufacturers and anyone using the material. Our leadership team established GRCUK from a start- up company in 2009 and built the business into a globally respected brand within 4 years. This was recognised by leading multi-national construction company Laing O’Rourke who purchased the manufacturing business in early 2014.

Our range of consultancy services includes:• Assisting manufacturers in establishment of production and

testing facilities.• Implementation of ISO 9001 compliant management systems and

progressing to certification.• Working with companies to achieve GRCA “Approved

Manufacturer” status. This is now considered to be the benchmark for any company serious about GRC production and features in most specifications.

• Development of DFMI protocol based manufacturing systems.• Working with architects to develop initial concepts and tender

information.• Advising contractors on procurement and supply chain

issues.• Laboratory testing in accordance with GRCA “Methods of

Testing”• On site testing including testing of post installed anchor

systems to reinforced concrete structuresThe above is not exhaustive and we can generally assist in anything connected to the manufacture or application of GRC products.

GRC DFMIWe can provide design engineering services to architects, main contractors or specialist sub- contractors at varying stages of a project. We do however recommend early involvement of an independent design consultancy such as ourselves given the potential for massive cost variations and delays if this is not addressed as soon as practical within the plan of works. Unless the GRC has been fully designed before it is put out to manufacturer tender, it will be impossible for anyone to provide accurate costs and will extend the procurement process.

Without a full design the manufacturer will have to make assumptions about:• Component/Panel Sizes • Thickness and strengthening of units.• Type of support/restraint system

This ultimately results in the manufacturer having to cost in all risks or apply significant qualifications to their quote. This can easily be avoided by early stage progression of the design.

RIBA STAGES 2-3Working in conjunction with the architects and other stakeholders we can develop layouts and

fixing methodologies to a point which will allow main contract tender with some element of accuracy. Once a main contractor is appointed more detailed design engineering can progress.

MAIN CONTRACTOR APPOINTMENT Once the construction work stage commences we can work with the successful contractor and other sub-contractors to complete a fully comprehensive design package. This will include general arrangement layouts, fixing details, builder’s works details and critically for the tender of the GRC package, component manufacturing drawings. This allows the GRC producers, installers and specialist sub-contractors to provided fixed price tender bids. It cannot be over stressed that without a fully design tender package, accurate or fixed prices cannot be submitted without all potential risks being included.

GRC MANUFACTURER/SUB-CONTRACTOR APPOINTMENTWhere no or little design and engineering work has been completed prior to the appointment of the GRC company we can of course provide support to the manufacture to produce general arrangements, fixing and component details.

At whichever point we become involved we always apply our Design for Manufacture and Installation (DFMI) approach. This allows for standardisation of manufacturing methods, fixing types etc. This method of design has been used by various industries (principally automotive) for many years and is proven to offer significant cost savings and efficiency improvements.

All our design works are carried out by highly qualified structural engineers and designers using the latest 3D modelling software for complete BIM integration.

DESIGNED FOR M

ANUFACTURE & INST

ALLA

TION

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GRC DFMI

DESIGNED FOR M

ANUFACTURE & INST

ALLA

TION

RIBA STAGE 2-3. GRCS appointed by architect to produce layouts, indicative fixing system, and typical component details

Main Contract tender and award

GRCS appointed by main contractor or specialist façade contractor

Production of all general arrangements, fixing and manufacturing details

Issue to GRC manufacturers or sub-contractors for accurate and fixed pricing

Contract completed at agreed and competitive fixed price.

RIBA STAGE 2-3. Architect details provided with possible assistance from manufacturers.

Main Contract tender and award

Main contractor or specialist sub contract façade contractor issues enquiry to GRC manufacturers.

GRC manufacturer provides prices based on information provided.

Option 1

Prices issued with all risks allowed for

Design works carried out by manufacturer or sub contract design engineer appointed by manufacturer

Option 2

Prices issued with qualified quote

Option 3

Prices issued without full consideration of what may be required.

Contract completed but at higher overall cost than may have been required

Contract completed but after possibly high variation costs agreed.

Financial losses to GRC manufacturer which may impact project delivery programme

GRCS DFMI APPROACH TRADITIONAL GRC PROCUREMENT APPROACH

It cannot be over stressed that without a fully design tender package, accurate or fixed prices cannot be submitted without all potential risks being included.“ ”

INSTALLATION & REPAIRS

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As part of our commitment to the GRC/GFRC industry we offer a range of site support services to manufacturers, main contractors, specialist façade companies or indeed anyone requiring assistance with any project featuring GRC products.

Installation of GRC is a very specialist activity and must be undertaken by skilled and compotent operatives who understand the properties of the material. Whilst GRC is very similar to natural stone and precast concrete in many aspects, there are certain characteristics of the material which have to be understood and factored into the installation process.

Our team have over 40 years’ experience in the fitting of natural stone and precast concrete and over the last five years have worked with our designers on a variety of GRC/GFRC projects throughout the UK using and developing our “design for manufacturing and installation” system.

We can offer a labour only install package or if required can discuss full sub-contract supply and fit sub-contracts for both Premix and Spray process GRC/GFRC products. (refer to page 12)

In addition to installation we can offer repair services to damaged GRC/GFRC components. Although GRC is a very durable material with high impact resistance unfortunately accidental damage post installation can occur and removal/replacement, whilst always preferable, is not always practical. In these circumstances we can look to provide on-site repairs with, where necessary engineering analysis to confirm any repair does not compromise the structural stability of the item.

SUPPLY & FIT SOLUTIONSWhere required we can offer a full sub-contract design, supply and installation service to main contractors and specialist façade sub-contractors. Working together with leading UK and European manufacturing partners we can combine our design, engineering and installation services into a total project managed sub-contract package.

In order to offer value security to customers and given the inaccuracy of providing prices without full design and fixing information being available we offer this service with full flexibility in regards contract progression.

On receipt of information regarding design intent and quantification we can provide a sub-contract price broken down into:

• Fixed Price design and engineering

• Budget prices for the supply and installation of GRC components and support system.

On completion of the fixed price design phase we will confirm our supply and installation price however customers have the right to compare these prices in the market using the completed details

as enquiry documentation. In the event more competitive quotes can be obtained (which we would always hope unlikely) the contract can be terminated (subject to agreed payment) and all design information provided to the preferred GRC manufacturer/sub-contractor

This method of sub-contracting GRC packages removes all tender risk, however involvement from very early in the main contract works is essential to integrate the processes into the project programme.

13

ANCHOR TESTING

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One of the most important aspects of GRC design is how the components going to be fixed to the building structure?

Products manufactured from GRC are substantially lighter than other forms of precast concrete; however with weights of approximately 60-100kg per m2 and the capability of most manufacturers to produce components of 6-10m2, support and restraint is one of the most important aspects of any given project. Typically the GRC element will be designed to span floor to floor and horizontally at slab level. Whilst restraint to transfer live loads can be made to both structures, secondary steel work or steel framing systems (SFS) usually the dead load is carried by, and transferred to the building structure.

Invariably this means the use of support brackets fixed back to the reinforced concrete frame. Whilst most manufacturers regularly test sockets cast into the GRC product there is a need to validate tensile pull out loads where post installed anchors are used to fix brackets to the structure. Ideally the design should be co-ordinated so cast in channels can be formed with the RC frame, however this isn’t always

possible. This leaves the installer having to drill the structure and fit expanding or chemical anchors.

Such fixings should always be tested by tensile proof loadings on a specified percentage of installed fixings. This is a requirement on any building covered by NHBC warranties.

GRC Synergies is a fully accredited Construction Fixings Association “Approved Tester”. As such we can offer an on-site testing service to anyone requiring proof loads on any post installed anchors used to fix GRC, or indeed any other components to a building structure.

All our proof load tests are carried out in accordance with CFA Guidance note “Procedure for SiteTesting Construction Fixings – 2012”

STONEWORK & MASONRY DESIGNGiven the synergy between GRC and natural/cast stone/precast cladding we can offer specialist design and engineering services to manufacturers where required to supplement in-house capabilities.

Our design team all have worked in these industries for many years and of course our structural engineers fully understand the properties of reinforced concrete. As such we can offer a range of services including:

• General layouts• Component and mould manufacturing details.• Support and restraint design.• Reinforcement design • Production of bending schedules.

We are happy to offer a full design service on any given project or indeed provide appropriate assistance as may be required by the manufacturers own design/engineering department.

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19© GRC Synergies Ltd 2014, all rights reserved

Please note Installation, Supply and Fitting Solutions are only available in the UK

Find us on

Head, UK & EU Office 4 Thornes Offices Park,Monckton Road,Wakefield,WF2 7AN

Tel: +44 (0)1924 367585Web: grcsynergies.comEmail: info@grcsynergies.com

Asia Office9th Floor, Zhonggauncun Chuangye Plaza26 Xinxi Road, HaidianBeijing,100085

Tel: +86 10 6297 9928