Analysis of Forming Difficulties of Double-Curved GRC Panels with Different Thicknesses: Material Properties and Process Adaptation Solutions

The thickness of double-curved GRC panels directly affects their forming difficulty, mechanical properties, and application scenarios. Components of different thicknesses require differentiated production process solutions. Based on 28 years of GRC production experience, Qinglong Group has thoroughly analyzed the forming challenges of double-curved GRC panels of different thicknesses and developed targeted process solutions, successfully achieving mass production of double-curved GRC panels ranging from 15mm thin to 50mm thick.

For thin double-curved GRC panels (15-25mm), the core of forming lies in preventing deformation. Such components are lightweight and flexible, but are prone to curvature deviations caused by uneven fiber distribution or curing shrinkage. In the Wuhan Han Show Theatre project, for the 15mm thick double-curved carved GRC panels, Qinglong adopted a high proportion of alkali-resistant glass fiber and ensured uniform fiber distribution through CNC spraying equipment, while applying a low-temperature slow-setting curing process to reduce shrinkage deformation. Combined with dedicated mold fixing frames, the curvature changes during the entire forming process were monitored, with timely adjustment and correction.

For thick double-curved GRC panels (30-50mm), the focus of forming lies in controlling compactness. Thick panel components require higher structural strength, but internal bubbles, delamination, and other defects are likely to occur during forming. In the Ouargla Hotel project in Algeria, for the 50mm thick double-curved hollowed-out GRC panels, Qinglong adopted a composite process of 'layered spraying + mechanical vibration', performing high-frequency vibration for every 20mm of sprayed thickness to ensure material compaction. At the same time, the aggregate gradation was optimized by selecting fine-grained quartz sand to improve material flowability and ensure smooth transitions of the double-curved surfaces.

Process adaptation and equipment upgrading are the key to forming panels across different thicknesses. Qinglong customizes dedicated production equipment for double-curved GRC panels of different thicknesses: thin panels use high-precision spray-up molding machines, while thick panels are equipped with large compression molding equipment. In the Hainan Poly Peninsula No. 1 project, mass production of 25-30mm thick double-curved panels was successfully achieved by adjusting the glass fiber content (≥5% for thin panels, ≥4% for thick panels) to balance forming difficulty and mechanical properties. Meanwhile, a thickness-curvature-process parameter database has been established to provide rapid adaptation solutions for different projects.

As a national Specialized, Refined, Distinctive, and Innovative (SRDI) enterprise, Qinglong leverages the R&D strength of its provincial-level engineering technology center to continuously overcome the forming technical challenges of double-curved GRC panels of different thicknesses. From the 15mm colored hollowed-out panels of the Nanning Liyuan Hotel to the 50mm thick hollowed-out panels of the Algeria project, Qinglong can provide the optimal thickness solution and forming process according to project requirements. Drawing on extensive project practice, Qinglong can offer designers and owners professional thickness selection advice, balancing production costs and construction feasibility while ensuring the desired design effect.