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Introduction to GFRP Rebars

GFRP (Glass Fiber Reinforced Polymer) rebars are advanced, non-corrosive reinforcing bars used in concrete structures. Unlike traditional steel rebars, GFRP rebars are made from high-strength glass fibers embedded in a polymer matrix, making them corrosion-resistant, lightweight, and durable. As industries search for cost-effective, long-lasting solutions, GFRP rebars are quickly becoming the go-to alternative for infrastructure, marine, and industrial applications.

Features

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Lightweight

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Corrosion-resistant

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Strong

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Cost-effective

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Low Maintenance

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Longer Life

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Easy Handling

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Strong Bond Strength

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Customised Lengths

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Non-Conductive

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Non-Magnetic

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Non-Electromagnetic

Manufacturing Process

Manufactured through a highly controlled pultrusion process Continuous glass fibres are drawn from spools and passed through a resin bath, where they are coated with a polymer resin, typically made of vinyl ester or epoxy
This resin-coated fibre bundle is then pulled through a heated die, which shapes it into the required diameter and ensures uniform coating of the resin around the fibers.
The die also initiates the curing process, where heat solidifies the resin to form a rigid, solid composite material Once the curing is complete, the GFRP rebar is cut to the desired lengths and surface-treated to enhance bonding with concrete.

Product Specifications

0.065

Kg/mtr

0.116

Kg/mtr

0.175

Kg/mtr

0.25

Kg/mtr

0.45

Kg/mtr

0.685

Kg/mtr

1.07

Kg/mtr

Upto 100 metres
(In coil form)

Upto 12 metres (In staight bars)

Technical Specification of GFRP Rebars

FRP Rebar (6, 8, 10, 12 mm)

FRP Rebar (16, 20, 25 mm)

Sr. No. Properties UOM Tolerance IS 18256 : 2023 TSL GFRP Rebar
1
Glass Content
%
±5
≥ 75
≥ 80
1
Tensile Strength
Mpa
min.
700 – 850
1100 – 1200
3
Tranverse Shear Tensile
Mpa
≥ 130
130 – 200 Mpa
4
Tensile Modulus of Elasticity
Mpa
≥ 45000
45000 – 55000
5
Ultimate Tensile Strain
%
≥ 1.1
≥ 1.1
6
Glass Transition Temperature
oC
≥ 100
101-115
7
Moisture Absorption (short hrs.)
%
min.
≥ 0.25
≥ 0.25
8
Moisture Absorption (Iong term)
%
min.
≥ 1
≥ 1
9
Alkaline Resistance
Mpa
≥ 80 % of mean
ultimate tensile force
of pristine bars
≥ 80 % of mean
ultimate tensile force
of pristine bars
10
Bond Strength
Mpa
≥ 7.6
8-15
Sr. No. Properties UOM Tolerance IS 18256 : 2023 TSL GFRP Rebar
1
Glass Content
%
±5
≥ 75
≥ 80
1
Tensile Strength
Mpa
min.
550-650
16 mm ≥ 700
20 mm ≥ 650
25 mm ≥ 650
3
Tranverse Shear Tensile
Mpa
≥ 130
135 – 200 Mpa
4
Tensile Modulus of Elasticity
Mpa
≥ 45000
45000 – 55000
5
Ultimate Tensile Strain
%
≥ 1.1
≥ 1.1
6
Glass Transition Temperature
oC
≥ 100
101-115
7
Moisture Absorption (short hrs.)
%
min.
≥ 0.25
≥ 0.25
8
Moisture Absorption (Iong term)
%
min.
≥ 1
≥ 1
9
Alkaline Resistance
Mpa
≥ 80 % of mean
ultimate tensile force
of pristine bars
≥ 80 % of mean
ultimate tensile force
of pristine bars
10
Bond Strength
Mpa
≥ 7.6
8-15

Benefits of GFRP Rebar

Common Issues

Problems with TMT Rebars

CORROSION

TMT bars are prone to corrosion when exposed to moisture, chemicals, or saline environments, compromising their strength and the structural integrity of buildings over time,

THEFT DURING TRANSIT AND ON-SITE

TMT bars are highly vulnerable to theft, especially during transit or at unsecured construction sites. Reports suggest theft rates can reach up to 20%, causing financial losses and project delays.

LABOR-INTENSIVE INSTALLATION

Handling, cutting, bending. and placing TMT bars demand skolled labor. making the process time-consuming and adding to overall project costs, especially in large-scale construction projects. The bending, cutting, and placement of bars demand skilled labor and may increase construction timeframes,

RISING COSTS

The cost of TMT bars is highly volatile due to fluctuating raw material prices, increasing transportation expenses, and rising labor costs. These factors contribute to unpredictable project budgets, making it challenging to mai ntain financial control over construction expenses.

CUTTING OF OPENING IN CONCRETE STRUCTURES

Incorporating openings, such as doorways or windows, in concrete structures with TMT bars can be labor-intensive and time-consuming, Special tools and techniques are often required for precise cutting, adding to construction complexity.

SCRAP GENERATION AND WASTE

Cutting and bending TMT bars to fit specific designs often generate significant scrapt creating waste management challenges and adding to project inefficiencies. The disposal of the scrap can be concern and wate management challenge.

MARKET PRICE VOLATILITY

Frequent fluctuations in TMT bar prices due to market dynamics can significantly impact construction budgets, requiring constant adjustments during procurement.
These challenges highlight the need for more innovative, cost-effective, and efficient alternatives like GIGABAR* GFRP Rebar by Aeron Composite, which address many of these concerns,

GFRP BAR vs TMT BAR / CRS TMT BAR
STAINLESS STEEL TMT BAR

PROPERTIESGrade 500GFRPCOMPARISON
Tensile strength MPa500 min800-1100Stronger
Weight/Meter 8mm0.395 kg0.099 kgLighter
Bar Length12 meterupto 100 metersBetter improvement
CostHigherLowerCost effective
Life Spend50 years(+) 80 yearsMore durable
Corrosion resistanceNoYesMore durable
Electric conductivityYesNoNo accidents risk
Thermal conductivityYesNoDoes not dissipate heat
Concrete covering35mm - 45mm20mmLower concrete volume
Shear Strength120170Higher
Bond strength MPa/N/mm2≥ 10≥ 7.6Lower
Compression MPa/N/mm2500450Lower
Modulus of Elasticity [Gpal160-20065Lower
Elongation [%]12% (min.)4% (max.)Lower
Density [ton/m3]7.81.9Lower
EMI/RFI TransparencyNOYesTransparent To EMI/RFI
Linear expansion coefficient, a*10-6/oC13-159-12Lower
Installation, Handling & Transport CostHighLowCost Effective
Environmental ImpactHighLow45% Less C02 emission

Spectrum of Applications

Marine & Coastal

Slab Culverts

Retaining Walls

Noise barriers

Box Culverts

Plain Concrete Components

Walkways of Foot Over Bridge

Crash Barriers & Bridge Parapets

Pedestrian Parapets and Railings

Approach Slabs

Slab Culverts

Slab Culverts

Slab Culverts

Slab Culverts

Slab Culverts

Slab Culverts

Tunnels and Underground Works

Deck slabs

Flooring

Septic Tanks

Boundary Walls

Treatment plants

Chemical & wastewater

Underground Water Tanks

Sewerage Treatment Plants

Roadways & Bridges

Drainage

Flooring

Parking Garages

Grade Slabs

Under Water Tanks

Swimming Pools

Sewage Treatment Plants

Pavements/lnternal Road

Industrial Plants

Tunnel Eyes

Noise barriers

Bridge Decks

Bridge Deck overlays

Panels and Copings

Retaining Walls

Crash Barriers and Bridge Parapets

Mechanically Stabilised Earth Wall

Infrastructure

Runways

Drains

Noise barriers

Deck Slabs

Non-Structural Walls

Underground Water Tanks

Sewerage Treatment Plants