What Are the Production Processes of GRC Manufacturers? Core Process Types and Qinglong Application Practices

The production processes of a GRC manufacturer directly determine product quality, the ability to achieve shapes, and applicable scenarios. The core processes fall into four major categories: spray-up process, premix casting process, compression molding process, and CNC engraving process, each with its own suitable scenarios and technical characteristics. As a manufacturer with mature craftsmanship, Qinglong masters all kinds of GRC production processes and can precisely match them to project requirements, achieving full-scenario coverage from standardized products to complex artistic components.

Spray-up process: the preferred choice for thin-walled, irregular-shaped components. Spray-up is one of the core GRC processes, in which high-pressure air sprays the GRC mix (cement slurry + alkali-resistant fiber + aggregate) into the mold. Its core advantage is achieving dense forming of thin-walled components (15-50mm thick) and complex cavities, suitable for double-curved curtain wall panels, hollow carved panels, artistic sculptures, and more. Qinglong's spray-up process adopts "high-pressure spraying + manual assisted vibration" with a working pressure of 0.3-0.5MPa, a spraying distance of 300-500mm, and a layer thickness of 10-15mm, avoiding hollowing and air bubbles. The 15mm thick GRC carved panels for Wuhan Han Show Theatre and the twisted double-curved exterior wall panels for Guangxi New Media Center were both produced with this process, perfectly balancing complex shapes and thin-walled structures.

Premix casting process: an efficient choice for standardized, thick-panel components. The premix casting process pours the well-mixed GRC blend into the mold and forms it after vibration compaction. It is suitable for standardized flat panels, thick-panel components (thickness ≥50mm), conventional decorative lines, etc., with high production efficiency and controllable cost. Qinglong's premix casting process is paired with automated mixing equipment and high-frequency vibrators (frequency ≥100Hz) to ensure the mix is uniform and dense, with component dimensional error ≤±2mm. The 19,800 square meters of GRC curtain wall flat panels for Shenzhen Longhua Xiangshan Science and Technology Park and the GRC railings for Zhongshan Kaiyin New Town were both mass-produced with this process, with a daily output of 1,000 square meters, meeting the large-scale delivery needs of major projects.

Compression molding process: an efficient process for texture simulation and mass-produced components. Compression molding places the GRC mix into pre-made molds and presses it into shape with a press machine. Its core advantages are high texture fidelity and good component consistency, suitable for stone-imitation, wood-imitation, European relief, and other products requiring mass replication of textures. Qinglong's compression molding process uses polyurethane molds with texture replication precision ≤0.1mm. For example, the GRC stone-imitation components for Dongting Lake Museum have a surface chiseled-stone effect fidelity of over 95%, mass-produced through the compression molding process, which ensures consistent quality while reducing cost. This process is suitable for batch decorative components of cultural tourism projects and commercial complexes, such as the GRC European-style components for Nanning Mingyue Lake European Style Town, where compression molding achieves an overall exotic atmosphere.

CNC engraving process: a precise process for complex textures and artistic components. The CNC engraving process engraves surface textures on formed GRC components with a five-axis engraving machine, suitable for complex needs such as high-precision relief, text patterns, and artistic shapes. Qinglong's CNC engraving process achieves a precision of ±0.5mm, enabling accurate rendering of fine textures and complex patterns. For example, the GRC antique bamboo slip components for Hainan Changying Global 100 Fantasy Park have surface text created by CNC engraving, with clear strokes and extremely high precision. Combined with the spray-up and premix casting processes, this process achieves dual precision of "shape + texture", such as the GRC public art sculptures for Shanghai Astronomy Museum: the main shape is first formed by spray-up, then the surface textures are refined by CNC engraving, making it a model of combining art and technology.

Process selection and Qinglong technical support: matching the optimal solution to needs. Qinglong's technical team recommends appropriate processes based on project requirements (shape, thickness, batch size, precision): spray-up for thin-walled irregular shapes, premix casting for standardized mass production, compression molding for texture simulation, and CNC engraving for fine artistic work. Meanwhile, Qinglong continuously innovates process integration, such as BIM technology + spray-up, optimizing the segmentation and production of double-curved components to improve efficiency and precision. With 28 years of process accumulation and project practice, Qinglong has become an "all-around manufacturer" of GRC production processes, able to provide mature process solutions for any requirement.