Key Takeaways:

• GFRP offers excellent corrosion resistance and a longer lifespan than steel, ideal for harsh environments.

• The higher initial cost of GFRP is offset by significant lifecycle savings.

• GFRP is lightweight, non-conductive, and has a much lower carbon footprint than steel.

• Steel remains necessary for seismic and heavy-load applications due to its ductility .

• India’s GFRP market is growing but needs more standards, investment, and policy support.

INTRODUCTION

India’s infrastructure and construction sector stands at a critical juncture, driven by the twin imperatives of sustainable development and long-term infrastructure sustainability. As climate challenges intensify, traditional steel rebar faces increasing issues with corrosion, especially in coastal and industrial environments, driving up maintenance costs. Although advancements such as epoxy coatings, galvanization, and corrosion-resistant alloys are helping extend steel’s lifespan, they add cost and complexity. Glass Fiber Reinforced Polymer (GFRP), being naturally non-corrosive, lightweight, and durable for over 75 years, is emerging as a likely alternative in harsh environments. While steel will continue to dominate in general construction, GFRP is gaining traction in critical infrastructure where long-term durability and low maintenance are priorities.

COMPARISON: GFRP V/S TRADITIONAL STEEL REBAR

REAL-WORLD EXAMPLES

International Projects

• Jizan Flood Channel, Saudi Arabia: Used 12+ million meters of GFRP to avoid corrosion.

• Burj Khalifa, UAE: GFRP used for lightweight, high-strength applications.

• Düsseldorf Metro, Germany: GFRP allowed tunnel boring machines to cut safely through non-metallic reinforcement.

Indian Projects

• Kochi Metro: Used in viaducts near the sea for corrosion resistance.

• Patna Metro: Integrated into monsoon-prone infrastructure.

• Chennai Airport Expansion: Used in TBM zones for safety and durability.

​SWOT ANALYSIS

​INDIAN PRODUCERS

Currently, very few Indian producers have responded in making a transition and are making investments by establishing high-end pultrusion plants and implementing it in a few infrastructure projects. ARC Insulations, founded in 2003, is India’s largest GFRP rebar and associated products producer with a comprehensive array of composite solutions. A portfolio of prestigious projects such as Mumbai Metro Line 3, Ahmedabad Metro, and Bengaluru Metro. Their production range covers different diameters (4 mm to 50 mm), and they are in line with global standards like ASTM D795.

Other major players are 7Star GFRP (Shri Rathi Group), Quad Composites (GetFiBAR), and a new entrant based on innovation, Olectra Greentech, which has diversified into manufacturing GFRP with considerable investment. These manufacturers are focusing on quality control , and ARC employs ISO 9001-certified procedures and stringent test protocols.

​INVESTMENT AND CAPACITY REQUIREMENTS​

Any transition requires a lot of planning, which involves a lot of investments and a lot of processes are involved. So, setting up such plants will require significant capital expenditure for a high-output pultrusion line. Additional investment is needed for compliance certification, marketing, and technical training. Raw material costs such as high-grade glass fibre and resins remain substantial, though domestic sourcing is gradually improving cost structures. As this may require a lot of imports, which don’t comply with the current vision of being self-reliant. Thus, as per, Industry reports, a well-utilised plant can achieve ROI within 4–6 years, especially when lifecycle cost benefits are factored into project planning. So, having a clear vision of total investment cannot be assumed it has to be properly listed so that we can have a proper valuation.

​POLICY IMPACT: PRESENT AND POTENTIAL

GFRP rebar has not yet been fully integrated into Indian standards like IS 1786, but the momentum for its adoption is growing. The Indian Roads Congress (IRC) has issued guidelines encouraging GFRP for marine and corrosive environments. GFRP usage is also supported by green procurement frameworks under IGBC and CPWD Green Ratings, which value reduced carbon footprints and durability. ARC’s Managing Director has even joined the BIS committee working on formal standards for GFRP, an important step toward regulatory recognition.

As GFRP rebar does not corrode and is non-metallic, its wider adoption might influence the National Scrap Policy by reducing the volume of metallic construction waste and shifting recycling priorities, ultimately supporting a circular and low-carbon economy. So, the investment done in this direction will be impacted, leading to losses and causing a hurdle.

CAN GFRP REPLACE TRADITIONAL STEEL REBAR?

Though, GFRP (Glass Fiber Reinforced Polymer) rebar has advantages in specific, high-corrosion environments due to its physical and chemical characteristics, such as in coastal infrastructure, sewage treatment plants, and underground metro systems. In these cases, where traditional steel often suffers from corrosion-related degradation, GFRP will have an advantage and has the capability to offer a durable, maintenance-friendly alternative with a longer service life.

The idea of full-scale replacement also encounters practical challenges. The steel industry has made significant investments in production infrastructure and design practices built around steel’s properties. Transitioning to GFRP will require time, education, regulatory alignment, and real-world validation. Hybrid systems that combine the strengths of both materials are already emerging as a practical step forward.

When it comes to high-ductility and seismic-critical structures such as high-rise buildings or earthquake-prone zones, traditional steel remains indispensable due to its well-understood behaviour under dynamic loading and its ability to absorb energy through plastic deformation. GFRP, being a linear-elastic material, lacks this ductility and is therefore not yet a one-size-fits-all replacement.

In conclusion, GFRP may not be a complete replacement for steel rebar, but it is a highly effective complementary material in the right applications. As design codes evolve and awareness grows, GFRP will increasingly find its place in the toolbox of modern, sustainable construction, particularly where corrosion resistance and lifecycle performance are paramount.

CURRENT MARKET

As per data sources, the GFRP rebar market has been estimated at around USD 2.1 billion in 2024, with a CAGR growth ranging between 6-13.5 % by 2032 and achieving USD 3.8 billion. Currently, the Indian market is much smaller but growing rapidly, valued at approximately USD 20 million in 2024 with a projected 17.3% CAGR through 2030. It has been anticipated that the growth has been propelled by metro expansions (e.g., Kochi, Patna, Delhi), NHAI road projects, and public tendering that now considers lifecycle costs and sustainability.

FUTURE OUTLOOK

GFRP is currently on a steady path toward broader adoption in India. In the coming 2-3 years, there will be a clear focus on standardisation and awareness through pilot projects. With progressing terms, cost competitiveness and proven performance will drive usage in corrosive environments. And finally, GFRP will be poised to become the go-to material for durability-focused infrastructure, with India potentially emerging as a global supplier. Currently, the transition to GFRP rebar in India is still in its initial phase, marked by early adoption and growing awareness. However, this transition will require sustained effort, industry alignment, and strong policy support, signalling a long but promising journey ahead.

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