What Is the GRC Production Process? Standard Workflow and Qinglong's Technical Innovation

The GRC production process is the core of ensuring product quality and performance. High-quality GRC must go through multiple standardized procedures, including design deepening, raw material preparation, molding, and curing, combined with advanced equipment and technological innovation, to achieve precise shapes and stable performance. Understanding the GRC production process helps assess a manufacturer's production capability and select products that meet project requirements.

I. Core Standard Process of GRC Production

GRC production begins with design deepening, converting project drawings into producible component drawings and using BIM technology to optimize shapes and segmentation to ensure production feasibility. In the double-curved GRC project of the Guangxi New Media Center, Qinglong achieved precise segmentation of complex shapes through BIM modeling. Next is raw material preparation: cement, aggregates, fibers, admixtures, and water are precisely measured according to the formula and mixed thoroughly in a twin-shaft compulsory mixer, with mixing time controlled at 3-5 minutes to ensure the materials are evenly blended. The molding process is selected according to component type; common methods include spray-up molding, premix casting, and press molding. Flat components mostly use premix casting, while complex-shaped components use spray-up molding. The GRC curtain wall panels for the Xiangshan Science and Technology Park in Longhua, Shenzhen, produced by Qinglong, use the spray-up molding process to ensure shape precision and uniform fiber distribution. After molding, curing is performed: first 24 hours of moist curing, then transfer to a constant temperature and humidity curing chamber for 7-14 days to ensure the strength meets standards. Qinglong's curing chambers maintain a temperature of 20-25°C and humidity ≥90%, ensuring full hydration of the components. Finally, surface treatment and quality inspection are carried out: after surface grinding and repair, indicators such as dimensional deviation, strength, and appearance are tested, and only qualified products may leave the factory.

II. Technical Key Points of Key Production Processes

The mixing process requires controlling the water-binder ratio and mixing speed. An excessively high water-binder ratio easily leads to shrinkage cracking, while an excessively low one results in poor flowability. Qinglong precisely controls these parameters through automated mixing equipment to ensure stable mix performance. The molding process requires controlling the uniformity of fiber distribution; during spray-up molding, spray pressure and angle must be adjusted to avoid fiber agglomeration. Qinglong uses dedicated spraying equipment, improving fiber distribution uniformity by 30%. The curing process is key to strength development: early moist curing prevents surface cracking caused by water loss, while later standard curing ensures the strength meets standards. Qinglong employs an intelligent curing system that monitors temperature and humidity in real time and automatically adjusts the curing environment. Surface treatment must ensure flatness and aesthetics, with deviations controlled within ±2mm; complex-shaped components require fine manual grinding. Qinglong has a professional surface treatment team to ensure component appearance meets design requirements. Quality inspection must cover multiple indicators including dimensions, strength, and appearance. Strength testing is conducted through random sampling and laboratory submission, with a required pass rate of 100%. Qinglong has established a three-level inspection mechanism to ensure the quality of products leaving the factory.

III. Innovation and Upgrading of Qinglong's GRC Production Process

Qinglong has carried out multiple technological innovations on the basis of traditional processes to improve production efficiency and product quality. It has introduced fully automated production lines, achieving full-process automation of raw material metering, mixing, molding, and curing, increasing production efficiency by 50% and raising the product pass rate to over 99.5%. It has innovated mold technology by combining polyurethane soft molds with steel molds to accommodate complex double-curved shapes, increasing mold reuse by 40%; for example, the Century Plaza project on Nanjing East Road in Shanghai used customized polyurethane molds to achieve precise reproduction of simulated tree textures. It has optimized fiber dispersion technology, developing dedicated fiber dispersants and mixing processes that significantly improve fiber distribution uniformity and increase component flexural strength by 20%. It has introduced a digital quality traceability system, assigning a unique identification code to each component and recording data from the entire production process, facilitating later traceability and maintenance and ensuring product quality is traceable.

IV. Process Adaptation for Different Types of GRC Components

Flat components: premix casting + automated curing process, offering high production efficiency and high dimensional precision. The flat GRC cladding panels of the Qiangwei Garden project in Zengcheng, Guangzhou, produced by Qinglong, adopt this process, with significantly increased daily output. Complex-shaped components: spray-up molding + manual repair + custom mold process to ensure shape precision. The carved GRC panels of the Han Show Theatre in Wuhan adopt this process, realizing the complex "Chinese Red Lantern" shape. Large components: modular production + on-site assembly process to reduce transportation and installation difficulty. The large GRC roof components of the Hainan International Convention and Exhibition Center adopt this process, improving construction efficiency. Colored GRC components: inorganic mineral pigments are added to the raw materials and a dedicated coloring process is used to ensure color uniformity and durability. The colored GRC panels of the Liyuan Hotel in Nanning, produced by Qinglong, adopt this process, with colors remaining vivid without fading for many years.