GFRC & Light Cast Architectural Products
Architectural Mall offers GFRC and Light Cast architectural products for custom decorative applications, including fireplace surrounds, mantels, window and door surrounds, dormers, range hoods, facade details, and other cast architectural elements. These concrete-based products provide a natural stone or cast architectural appearance with less weight than traditional solid stone or cast stone.
Depending on the project, products may be made using GFRC or Light Cast methods. Cast stone is included here only as a comparison point because many customers use it as a reference when evaluating weight, appearance, and installation requirements.
What Is Light Cast?
Light Cast is a hybrid architectural product made with a poured GFRC-based face and an EPS foam core or backing. This construction gives it added support compared with traditional sprayed GFRC, while keeping it a fraction of the weight of solid cast stone.
Light Cast is commonly used for decorative architectural products where appearance, weight, handling, and ease of installation matter.
Products made in Light Cast may include:
- Fireplace surrounds, mantels, and overmantels
- Window and door surrounds
- Dormers and cupolas
- Range hoods
- Ceiling elements
- Custom architectural details
Available finishes include smooth, distressed, and sandblasted. Custom colors and color matching may be available depending on the project requirements
What Is GFRC?
GFRC stands for Glass Fiber Reinforced Concrete. It is a concrete-based material reinforced with glass fibers, allowing architectural pieces to be made thinner and lighter than solid cast stone while still maintaining a durable, stone-like appearance.
Traditional GFRC is typically produced as a sprayed reinforced shell, which helps reduce weight compared with solid concrete or cast stone. It can mimic the look, texture, and color of natural stone and is commonly used for larger architectural elements, facade components, exterior accents, and decorative column covers.
GFRC products can be made from standard or custom molds, allowing Architectural Mall to create stone-like architectural details for both standard and custom project applications. Common GFRC applications include architectural column covers, facade elements and exterior accents, exterior panels, window and door surrounds, balustrades, and custom architectural details..
Important note:
Architectural Mall’s GFRC columns are supplied as decorative column covers in halved sections and are not load bearing.
Typical GFRC Properties
GFRC is lighter than solid concrete or natural stone, with typical weights around 2.5–4.5 lbs per sq ft, depending on thickness. Shell thickness commonly starts around 3/8″, and compressive strength is typically around 9,500 PSI, depending on the product and project requirements.
Because GFRC is concrete-based, it will not burn. Any project-specific fire rating should be confirmed before specification.
Light Cast vs. GFRC vs. Cast Stone
| Category | Light Cast | GFRC | Cast Stone |
|---|---|---|---|
| Simple explanation | Lightweight GFRC-based product with a poured concrete-based face and EPS foam core or backing | Glass Fiber Reinforced Concrete; a concrete-based material reinforced with glass fibers | Solid cement-based material used as a traditional stone-like option |
| Best for | Decorative surrounds, mantels, range hoods, dormers, cupolas, ceiling elements, and custom details | Column covers, facade elements, exterior panels, accents, balustrades, and custom architectural details | Heavy masonry-style decorative pieces where a traditional solid stone appearance is the priority |
| Weight | Typically the lightest option because of the EPS foam core or backing | Lighter than solid cast stone or cast-in-place concrete | Typically the heaviest option |
| Construction | Poured/cast into a mold with a concrete-based face and lightweight EPS foam backing or core | Commonly made as a thin reinforced shell using a spray-up GFRC process; premix methods may also be used depending on the product | Solid poured cement-based material |
| Load bearing | No; used for decorative architectural products | No for Architectural Mall’s GFRC column covers; they are decorative covers supplied in sections | Not typically used as a structural element unless specifically engineered for that purpose |
| Custom designs | Yes; custom shapes, profiles, finishes, and colors may be available | Yes; custom architectural details, finishes, and colors may be available | Varies by product and manufacturer |
The main difference is weight and application. Cast stone is the heaviest option and is often chosen when a traditional solid stone appearance is the priority. Traditional GFRC reduces weight through a sprayed reinforced shell while maintaining a durable, stone-like appearance, making it well suited for column covers, facade elements, and exterior architectural details. Light Cast reduces weight further with an EPS foam core or backing, making it a practical choice for decorative architectural details where weight, handling, and installation ease matter.
Common Light Cast & GFRC Application
Fireplace Surrounds & Mantels
Light Cast is well suited for fireplace surrounds, mantels, and overmantels because it provides a cast architectural appearance without the full weight of solid stone. Because the material is concrete-based, it is also naturally non-combustible
Range Hoods
Custom range hoods can be fabricated with a cast architectural look while keeping weight manageable for interior installation. This is important when the piece needs to be secured to cabinetry, framing, or a wall without adding unnecessary weight.
Exterior Facade Details
GFRC and Light Cast products can be used for custom exterior facade details such as arches, cornice, balcony trim, panels, and decorative architectural accents. These materials provide a stone-like appearance without the full weight of solid stone.
GFRC Columns
GFRC column covers are available for projects that need a natural stone-like column appearance. They are supplied in halved sections that wrap around existing structural supports and are not load bearing.
Facade Elements & Architectural Accents
GFRC and Light Cast products can be used for custom facade elements, exterior accents, panels, surrounds, and decorative architectural details where a concrete-based appearance is desired without the weight of solid stone.
Custom Architectural Details
For projects requiring a specific profile, historical detail, or ornamental shape, custom molds can be made from drawings, photos, dimensions, or existing samples.
Send Us Your Drawings, Photos, or Measurements
Not sure whether your project needs GFRC, Light Cast, or another material? Send us your drawings, photos, measurements, design references, or existing samples. Architectural Mall can review the application and help recommend the right product, mold approach, finish, and color option for your project
Call 877-279-9993 or email us with your project details
FAQ
What is Light Cast?
Light Cast is a lightweight architectural product that uses a concrete-based GFRC face with an EPS foam core or backing, depending on the design. It is used for decorative products where reduced weight helps with handling and installation.
Is Light Cast the same as GFRC?
Not exactly. GFRC is the broader material category, while Light Cast is a lightweight GFRC-based product style. Light Cast is related to GFRC, but not every GFRC product is Light Cast.
Is Light Cast the same as cast stone?
No. Cast stone is typically solid and heavier. Light Cast provides a cast architectural appearance but uses a lighter construction method to reduce weight.
Is Light Cast used for columns?
No, Light Cast is not used for columns. For column applications, Architectural Mall offers GFRC column covers, fiberglass columns, synthetic stone columns, and other options depending on whether the column is decorative or load bearing.
What is GFRC used for?
GFRC can be used for architectural column covers, facade elements, exterior panels, window and door surrounds, fireplace surrounds, balustrades, and custom architectural details.
Are GFRC columns load bearing?
Architectural Mall’s GFRC columns are decorative column covers supplied in sections and are not load bearing. For load-bearing applications, fiberglass or synthetic stone column options may be more appropriate.
Can Light Cast be used outside?
Many Light Cast products are designed for both interior and exterior decorative applications, depending on the product design, finish, and installation method. Contact Architectural Mall to confirm the best option for your specific project.
Can you make custom Light Cast or GFRC designs?
Yes. Custom designs are available. Send drawings, photos, dimensions, or existing samples, and Architectural Mall can review the project and recommend the best material and mold approach.
What finishes are available?
Available finishes may include smooth, distressed, and sandblasted textures, along with standard or custom-matched colors depending on the product and project requirements.