Foam Core GFRC Construction Course
Learn professional foam core construction techniques for manufacturing lightweight GFRC products. Discover how to build strong, lightweight concrete benchtops, furniture and architectural elements using proven commercial methods.
Learn Directly From Us
Learn the foam core methods we've refined through years of commercial GFRC production, taught by the developemtn team.
Industry Experience
Built on techniques developed through 15+ years of manufacturing lightweight architectural concrete.
Real Studio Methods
Follow the same proven workflows we use every day to build strong, lightweight GFRC products in our commercial manufacturing studio.
What You'll Learn
Learn our complete foam core construction process for creating lightweight, high-strength GFRC countertops, vanity tops and architectural products.
Foam core design principles
Selecting and preparing EPS foam
GFRC mix design and materials
Hand and planetary mixing techniques
Foam core casting methods
Countertops, waterfall ends and vanity tops
Demoulding lightweight GFRC products
Reducing weight without compromising strength
"Once you understand foam core construction, you'll never look at thick concrete the same way again. You can achieve the same visual impact with a fraction of the weight."
Philip Mark Martin
Course Instructor, Concrete Studio Director
Course Outline - What You'll Learn
MODULE 01
Foam Core Countertop
Learn the complete process for producing a lightweight foam core countertop using GFRC, from preparing the foam through to final trowelling.
You'll Learn
Measuring and preparing the foam core
Levelling the GFRC backing coat
Positioning the foam correctly
Filling the perimeter and encapsulating the foam
Trowelling the rear surface
Creating vent holes for steam release
MODULE 02
The GFRC Mix Design
Learn the materials, mix design and preparation methods used to produce consistent, high-quality GFRC for foam core construction.
You'll Learn
Understanding GFRC ingredients and material selection
Premix versus mixing your own blend
Mixing with an electric hand mixer
Mixing with a planetary mixer
Preparing separate face coat and backing coat mixes
MODULE 03
GFRC Casting
Learn the complete casting process used for foam core products, including face coats, backing coats and integrated vanity tops.
You'll Learn
Spraying and brushing the face coats
Applying the fibre-reinforced backing coat
Casting around integrated basin moulds
Building consistent concrete thickness
Completing the full vanity top casting process
MODULE 04
Demoulding
Learn how to safely remove foam core products from their moulds while protecting the fresh concrete.
You'll Learn
Preparing pieces for demoulding
Safely flipping countertops
Removing mould components without damage
Demoulding integrated vanity tops with basins
Supporting pieces during curing
Learn Online
Whether you're looking to learn the fundamentals of GFRC or want access to every future course we release, there's an option to suit your goals.
All Current and Future Courses Included
$495
All Access: Complete GFRC Course Library
Everything included in Introduction to GFRC
Lifetime access to every future course
Access to all future course updates
Member Q&A sessions and webinars
Early access to new course releases
Help shape future course content
Refundable against any future in-person workshop
4 Modules
$95
Foam Core GFRC Construction
Instant access to the complete course
Learn the exact methods used in our workshop
Detailed video and written training modules
Lifetime access and future course updates
No adverts or unnecessary filler
Refundable against any future in-person workshop