RENCO’s Advanced Composite Block Apartment
infos
A 96-unit, four-building apartment complex constructed in record time using a patented mineral composite fibre-reinforced material (MCFR). RENCO USA spent over a decade securing certification for use in the US, meeting stringent High Velocity Hurricane Zone requirements in Florida’s building codes.
location
West Palm Beach, FL, USA
company
RENCO USA
year
2024
The Cité Scolaire Internationale Jacques Chirac
infos
A shading and cladding project for an international school building.
location
Marseille, France
company
General Contractor: Bouygues Bâtiment Sud-Est
Architects: Rudy Ricciotti, Carta, Reichen et Robert Associés
year
2024
One Thousand Museum
infos
Glass fibre-reinforced concrete serves as both formwork and architectural finish, progressing up the tower during construction.
location
Miami, FL, USA
company
Zaha Haddid
year
2020
ABN AMRO
infos
Redevelopment of ABN AMRO’s offices on Foppingadreef in Amsterdam Zuidoost. This energy-efficient project prioritises circular design and sustainability, targeting completion in 2027, three years ahead of the Paris climate agreement goals and ABN AMRO’s own targets.
location
Foppingadreef, Amsterdam, Netherlands
company
Holland Composites, Broekbakema Architects, BTC Architects
year
In production (expected 2027)
633 Folsom
infos
Redevelopment of 633 Folsom, which included modern design elements to enhance the building’s functionality and aesthetics.
location
San Francisco, CA, USA
company
Permasteelisa Group
year
2020
Fa-Bo
infos
Renovation of a rigid-frame RC structure office building to improve earthquake resistance using carbon fibre. The interior was transformed into a museum.
location
Nomi, Ishikawa Prefecture, Japan
company
Kengo Kuma
year
2015
Carbonhaus
infos
The world’s first building made entirely of carbon fibre-reinforced concrete, located on the campus of the Technical University.
location
Dresden, Germany
company
HENN
year
2022
Residential Carbon Fibre Hurricane Damage Strengthening
infos
The carbon fibre strengthening system, consisting of CFRP fabric impregnated with epoxy resin, was applied to prepared concrete surfaces, including bond beams, columns, and walls. This material was strategically placed to provide additional flexural and shear strength, restoring structural integrity to the damaged elements.
location
Outer Banks, NC, USA
company
Structural Reinforcement Solutions
year
2022
Harkers Island Bridge Project
infos
Replacement of two ageing bridges as part of an initiative by the North Carolina Department of Transportation (NCDOT). The new bridge increases capacity for emergency access and evacuation, reduces congestion for marine vessels and vehicular traffic, and provides a direct path for drivers travelling between the mainland and Harkers Island.
location
Harkers Island, NC, USA
company
Balfour Beatty
year
2024
SUREbridge
infos
SUREbridge, with InfraCore®Inside, reinforces existing concrete bridge decks with thin composite layers or replaces the decks entirely with composite solutions, reducing weight while improving durability. This project refurbished four bridges.
location
Norway
company
SAMI Composites B.V. (FiberCore Europe), managed by MSS
year
2024
The White Bow
infos
This project features an impressive 340 m² curved, self-supporting canopy constructed with composite materials, evoking the image of a ship sailing at sea.
location
Valencia, Spain
company
Gurit Kerdyn
year
2019
Network Rail Flow Footbridge
infos
An innovative footbridge that improves safety, reduces costs, and transforms rail crossings.
location
Shropshire, UK
company
Network Rail, Knight Architects
year
2023
The Carbon House
infos
Home to the world’s largest self-supporting cantilever roof, produced using carbon fibre for Saudi Aramco.
location
Dammam, Saudi Arabia
company
DAR under Aramco; Composite parts by BFG International
year
2022
Steve Jobs Theater
infos
The structure features 44 equal panels, each 23 m long, and a single centrepiece panel.
location
Cupertino, CA, USA
company
PCT
year
2017
Caerostris Wall E+
infos
A single-family home built using composite materials.
location
France
company
Caerostris / Groupe Solutions Composites
year
2023
Swanston Square Apartment Tower
infos
A 34-storey building housing 536 residential apartments. Its striking façade features a portrait of Wurundjeri elder William Barak, exemplifying the integration of art and architecture.
location
Melbourne, Australia
company
Developer: Grocon
Architect: ARM Architecture
Main Contractor: Probuild
Structural Engineer: Aurecon
Façade Fabrication: ShapeShift Technologies
year
2015
Hill House
infos
An office block converted into a residential building. Two additional floors were added, requiring reinforcement of existing support columns, crack repairs, and support beams strengthened with carbon plates.
location
North London, UK
company
Composites Construction UK
year
2024
One Blackfriars
infos
A mixed-use building featuring composite materials in its façade and structural elements to achieve unique design and energy performance.
location
London, UK
company
SimpsonHaugh and Partners
year
2018
3D printed Home
infos
Homes built for the Community First Village to support homeless individuals, featuring innovative 3D-printed exteriors.
location
Austin, TX, USA
company
Designtrait, Fazio Architects, Black + Vernooy, Michael Hsu Office of Architecture, Thoughtbarn, Jobe Corral Architects, Chioco Design, McKinney York Architects.
year
2022
UAE Pavilion at Expo 2020 Dubaï
infos
A striking pavilion designed and built for the World Expo, showcasing innovation in composites.
location
Dubai, UAE
company
Santiago Calatrava; Composite panels by Premier Composite Technologies
year
2020
Tempere Deck and Arena
infos
The roof structure, built using composite materials, provides lightweight strength for large spans.
location
Tampere, Finland
company
SRV
year
2021
Statue of Liberty Museum and Secondary Screening Facility
infos
Incorporation of a carbon fibre grid technology to enable CarbonCast precast concrete walls with superior strength and thermal efficiency.
location
New York, NY, USA
company
Altus Group, Chomarat
year
2019
Latitude @ The Berkeley Building
infos
Upgrade and extension of the 1970s Berkeley Building, featuring the design and installation of 1,500 m² of a “flowing, curvy horizontal signature” façade. The project combined modernisation with aesthetic improvements.
location
Paris, France
company
Studios Architecture, Sika
year
2022
The Avenues Mall – Decorative Ceiling Crowlings
infos
Manufactured as FRP PET foam sandwich panels using CNC tooling and an open mould hand lay-up process. BFG delivered 14 full-size cowlings (26 x 12 m each) and four half-size units, totalling 5,120 m². Each unit comprised a perfect jigsaw of 12 smaller FRP sandwich pieces sculpted into chrome-finished panels. The panels are fire-resistant to BS 476 Part 7 Class standards.
location
Kuwait
company
Gensler Engineering
year
2017
Wolverhampton Tower Blocks
infos
Structural reinforcement using carbon fibre.
location
Wolverhampton, UK
company
Composites Construction UK
year
2022
Custom carbon fibre strengthening from Composites Construction UK.
Wall E+ – A Glass-Reinforced Pultruded Composite-Building System
Weight
The lightweight design reduced material weight, simplifying transportation and installation. The high strength-to-weight ratio provided structural durability without adding bulk. cost
Construction time was reduced due to prefabrication and modularity, accelerating project timelines. Minimized thermal bridges eliminated common points of heat loss, leading to greater energy savings. durability
The building system demonstrated resistance to weather and fire, performing well under extreme conditions such as moisture and heat, with an REI 30 fire resistance rating. maintenance
The design supports circular and sustainable construction, focusing on modularity, reuse, and a reduced environmental impact. LCA/Environmental Impact
The use of composites enhanced thermal insulation, providing superior energy efficiency with minimal material thickness. other
Fast and easy assembly was achieved through optimisation for off-site construction, requiring minimal on-site labour. The system integrated multifunctionality, accommodating solar panels, green walls, and other sustainable features. It also offered aesthetic and design versatility, enabling complex and modern architectural styles.GRP (Fibreglass Reinforced Plastic)
Weight
The canopy weighed half as much as a steel equivalent. Lightweight materials reduced transport weight, simplifying logistics. cost
The reduced weight eliminated the need for bulky auxiliary supports or pillars, simplifying structural complexity and reducing costs. durability
The canopy was designed to withstand variable weather conditions, significant thermal cycling, and heavy loads, such as snowfall. maintenance
Low to no maintenance is required compared to steel. LCA/Environmental Impact
Made from up to 100% recycled PET using Gurit Kerdyn™ Green, the canopy reduced the carbon footprint while utilising recycled materials effectively. It also provided excellent thermal insulation, contributing to energy savings and enhancing environmental performance. other
Prefabricated parts facilitated faster on-site assembly. The innovative design showcased architectural possibilities unavailable with traditional materials.GFRP Sunshades
Weight
The sunshades were light enough to comply with earthquake codes, which would not have been feasible with other materials. cost
Other solutions, such as GFRC, would have required additional supports, significantly increasing costs. durability
The airfoil-shaped design provides weather resistance. maintenance
The FRP sunshades require low maintenance compared to metal alternatives. LCA/Environmental Impact
Using traditional materials would have required additional support, regulation, installation equipment, and maintenance. This composite solution provided a more sustainable approach while passing fire safety standards. other
FRP panels with Silicate crystals affixed to a curtain wall
Weight
The use of FRP saved 500 tons of steel support structure compared to traditional materials. cost
Significant cost savings were achieved in infrastructure, plant equipment, and installation time. durability
The panels are resistant to extreme weather conditions. maintenance
Minimal to no maintenance is required, unlike steel, which is prone to corrosion. LCA/Environmental Impact
The lightweight panels reduced the need for transport and installation equipment. They are expected to require no replacement for 50 years.
Fire, Smoke, Toxicity. This was the first solution to offer high-rise composite façades compliant with building code fire regulations.
other
Lightweight and easier to install compared to traditional materials.Carbon Fibre and CFRP ribs and arches.
Weight
Traditional materials, such as concrete, would require intermediate supports or pillars, while steel structures are bulky and heavy. Carbon fibre enables large open spaces without the need for heavy support elements. cost
Although the upfront cost of carbon fibre composites is higher, they significantly reduce installation costs, construction time, and equipment needs. Additionally, carbon fibre allows for innovative design features that would otherwise be impossible or cost-prohibitive with traditional materials. durability
Carbon fibre composites are highly durable and resistant to variable weather conditions, thermal cycling, and corrosive environments. maintenance
These structures are low-maintenance or maintenance-free and can be equipped with sensors to monitor long-term performance. LCA/Environmental Impact
Carbon fibre composites have a lower CO₂ footprint compared to traditional materials. Advancements in recycling enable carbon fibre and resin recovery for reuse in high-value applications, improving end-of-life disposal sustainability.
Fire, Smoke, and Toxicity : all carbon fibre composites comply with local fire safety standards and regulations, meeting or exceeding the benchmarks set for traditional materials.
other
CFRP – Carbon Fibre Roof, Glass Walls With a Beam-Free Design
Weight
The carbon fibre roof weighs 80 tons, representing a 51% reduction in mass compared to traditional materials. This allowed for the creation of a roof with no internal floor support, a feat impossible with traditional materials. cost
While the raw material cost of CFRP is higher than traditional materials, the design freedom, weight savings, and other benefits significantly reduced downstream costs. The project required only 45 panels and 38 support brackets, compared to 452 panels and 1,800 brackets with traditional materials. The roof was assembled and lifted as a single unit, reducing installation time to just 2.5 hours—a timeline unachievable with traditional methods. durability
The carbon fibre composite panels meet all weather and environmental requirements, ensuring long-term performance. maintenance
Minimal to no maintenance is required over many years, as is typical with composite parts. LCA/Environmental Impact
Composites have a lower CO₂ footprint and are fully recyclable. In the future, the carbon fibre can be recovered and repurposed for other high-value structural applications instead of being disposed of in landfill. other
Carbon Fibre Reinforced Polymer (CFRP) Strands.
Weight
The integration of carbon and glass fibre reinforcement in this "no steel design" significantly improved weight efficiency compared to traditional materials. cost
Although the initial cost of composite rebar was higher, the weight reduction and nearly maintenance-free lifespan made composites a cost-effective choice for this coastal application. durability
The use of composite materials ensures a significantly longer lifespan than conventional materials. maintenance
In highly corrosive coastal environments, composite reinforcements eliminate steel corrosion, which typically damages surrounding concrete and leads to expensive repairs. LCA/Environmental Impact
A longer, maintenance-free lifespan reduces overall costs, extends functionality, and contributes to a reduced CO₂ footprint. other
Unique fire-retardant bio-composite brand Duplicor.
Weight
The use of composites kept the weight low, even with the incorporation of solar panels and moving parts, achieving a unique architectural design. cost
A cost effective solution to complex environmental, structural & fire specs. Designed for quick installation and simpler installation, costs were saved versus traditional materials. durability
The façade was engineered for a long lifespan, with corrosion resistance serving as a benchmark for future projects. maintenance
Despite the complexity of the design and the use of high levels of recycled materials, the solution ensures very low maintenance and cost over its lifetime. LCA/Environmental Impact
Produced with recycled and bio-based materials, this sustainable solution achieved 87.91% in the evaluation process and was awarded the "Outstanding" rating in the BREEAM Certificate (960-NBN-2014). other
ShapeShell™ RT, reinforced thermoset composite by ShapeShift Technologies
Weight
The panels were lightweight and structurally stiff to allow minimal fixing only at panel edge. Glasss-fibre reinforced concrete (GRC), would allow the double curvature design, but would need much heavier support beams, increasing structural load, as well as handling and installation needs. cost
The lightweight nature of composites and durability can lead to cost savings in transportation, handling, and long-term maintenance. durability
The material is engineered for enhanced durability, offering resistance to corrosion, moisture, and chemicals, which contributes to its longevity and reduces the need for frequent replacements. maintenance
Due to its resistance to environmental factors and impact, minimal maintenance is required, leading to reduced long-term upkeep costs. LCA/Environmental Impact
ShapeShell™ RT incorporates recyclable components and is designed to be lightweight, resulting in lower emissions during transportation and a reduced environmental footprint over its lifecycle. other
ShapeShift collaborated closely with ARM Architecture, Aurecon, and other stakeholders to overcome technical challenges, ensuring the façade met both aesthetic and performance expectations.65-Metre Long Wings: Moulded Hybrid Carbon and Glass Fibre-Reinforced Shells
Weight
The 28 wings, measuring up to 65 metres in length, were lifted and placed as single pieces. cost
While cost was not a primary driver for using composites, the building could not have been designed in the same way with heavier materials. In typical projects, the additional costs of pushing design and creative boundaries with traditional materials would have been prohibitive. Composites enable design freedoms not achievable with other materials. durability
The wings were designed to withstand high temperatures and thermal cycling. maintenance
The only realistic maintenance-free option. LCA/Environmental Impact
Accredited with LEED Platinum Certification and compliant with the Dubai Green Building Regulations and Specifications. other
Carbon Fibre
Weight
A simple solution that does not add significant weight to the structure. cost
This approach avoided the need for demolition and rebuilding, offering a substantial cost advantage. durability
Composite materials ensure long-term resistance to harsh coastal weather and saltwater exposure. maintenance
The wrapping eliminates the need for demolition, protects pillars from future degradation, and extends the building’s lifespan. LCA/Environmental Impact
This solution reduced environmental impact by avoiding demolition, extending the structure’s lifespan, and eliminating the need for rebuilding. other
Carbon fibre epoxy wrap/plates.
Weight
Carbon wrapping added minimal weight, avoiding the need for additional steel beams. cost
This solution made the project feasible. Without composites, traditional materials could not have achieved the required load-bearing capacity. durability
Repurposing the building extended its lifetime, while the wrapping strengthened the structure and reduced its vulnerability to future damage. maintenance
Carbon wrapping protects exposed concrete beams, reducing future damage and degradation. LCA/Environmental Impact
Extending the life of an 11-storey building has a significant environmental impact compared to demolition and rebuilding. Structures strengthened with carbon fibre require fewer repairs and maintenance, providing cost savings over the lifespan of the structure. other
Composite panels comprised of chopped strand glass reinforcement and polyester resin.
Fibre-reinforced polymers and glass fibre-reinforced concrete.
Weight
The swimming pool formwork could only remain unsupported when made from composites, enhancing the visual appeal. cost
Producing the parts from composites simplified installation, reduced lifting gear requirements, saving time, and provided transport benefits—all contributing to a cost advantage over concrete. durability
Maintenance-free in a relatively corrosive environment. Metal elements would have been prone to regular maintenance needs. maintenance
The only realistic maintenance-free option. LCA/Environmental Impact
Lightweight, easy to transport, and simple to install, the composite parts are likely to outlive the building. other
FRP PET foam sandwich panels.
Weight
FRP provided the appearance of metal without the associated weight and cost. cost
Producing these elements from metal would have necessitated roof structure reinforcement, significantly increasing project costs. durability
The parts were designed to withstand environmental conditions and were robust enough to prevent damage during transport. maintenance
No maintenance is required for the composite parts. Metal alternatives would have required regular inspections to check for degradation. LCA/Environmental Impact
Using traditional materials would have required additional support, regulation, installation equipment, and maintenance. This composite solution was less challenging and had a reduced environmental impact.
Fire, Smoke, Toxicity : this was the first example of sculpted chrome-finished panels that are fire-resistant to BS 476 Part 7 Class 2.
other
Glass Fibre
Glass fibre reinforcement
NORCO Infused Laminate and High-Performance Foam Core
Weight
Self-weight deflection issues, typically associated with steel, were avoided. cost
Seamless assembly reduced installation time. Cost-effective tooling and lighter support pillars minimised expenses. durability
The structure was designed to withstand wind, snow, thermal stresses, and vehicle impacts. maintenance
No maintenace versus stainless steel. LCA/Environmental Impact
The lightweight design simplified transport and installation, avoiding road closures. Such efficiencies are only achievable with composites. other
The canopies achieved a metallic look through durable metal spray coatings.Rockpanel Woods & Caramel Oak + Rockpanel Backboard Facade.
Patented Mineral Composite Fibre-Reinforced (MCFR) Building System from RENCO USA Inc.
Weight
FRP bricks are 75% lighter than concrete alternatives, allowing larger bricks to be used and speeding up construction time. cost
Material costs were reduced by 25% per square foot compared to traditional materials, with additional savings in time and waste reduction. durability
In addition to hurricane tests, the solution has been tested to confirm pest, mould and mildew resistance. maintenance
No post-production maintenance is required. LCA/Environmental Impact
The construction process fosters a cleaner environment with minimal waste, no cutting, and a green manufacturing process that uses recycled materials with a lower carbon footprint. other
FRP bricks facilitate faster and more efficient construction compared to traditional methods.Carbon fibre reinforced concrete
Weight
A quarter of the weight compared to steel-reinforced concrete. cost
Incorporating the walls and roof as a single entity saves time. Lighter parts significantly reduce costs, even when accounting for the higher expense of carbon fibre as the reinforcing material. durability
Designed to withstand variable weather, significant thermal cycling, and heavy loads. maintenance
Low to no maintenance is required compared to steel reinforcement. LCA/Environmental Impact
Components and structures can be designed thinner, achieving material savings of 50% or more. This reduces CO₂ emissions and the consumption of other valuable resources, such as water and sand. other
This material offers 30% less global warming potential. Carbon fibre’s thermal conductivity could also be utilised to help heat buildings.Lightweight Fibre-Reinforced Polymer (FRP)
Weight
Composites are 50% lighter than steel, enabling concrete-free foundations, reducing the need for heavy installation equipment, and minimising ground loads. cost
The system is projected to cost 40% less than standard steel footbridges due to reductions in material, production, and installation expenses. durability
Composites are resistant to corrosion and environmental damage, ensuring a long lifespan with minimal degradation over time. maintenance
The embedded fibre-optic monitoring system minimises the need for manual inspections, and the modular design allows for easy upgrades or redeployment. LCA/Environmental Impact
The use of FRP reduces the carbon footprint by eliminating concrete, minimising site waste, and allowing materials to be repurposed or relocated, ensuring sustainable lifecycle management. other
3D printed from Actual Recycled Consumer Waste™ based on recycled post-industrial Polypropylene.
Bespoke Carbon Fibre Strengthening materials.
Weight
Carbon wrapping and anchors added very little weight, whilst limiting the need to add additional steel beams or reinforcements. cost
A lightweight and quick solution, a 22 storey building was completed in 3 days without disruption to residents. durability
The solution is certified and maintains safety of the entire structure for many years. maintenance
The carbon wrapping helps to strengthe the building beyond the pre-renovation level. LCA/Environmental Impact
New fire-safety regulations required the installation of modern sprinkler systems. The structural damage created by this installation needed to be mitigated and carbon epoxy strengthening was the simplest, quickest and most cost-effective way to achieve this. other