What Is the GRC Production Process? A Comprehensive Analysis of the Manufacturing Workflow and Key Technical Points of GRC Materials

What is the GRC production process? A comprehensive analysis of the manufacturing process and technical key points of GRC materials

As an industry leader with 28 years of experience in detailed design, manufacturing, construction and installation, and after-sales maintenance in the field of UHPC/GRC/GRG/GRP materials, Qinglong Group (hereinafter referred to as Qinglong) has always been committed to providing expert solutions for designers and owners. GRC (Glass Fiber Reinforced Concrete), as a new type of architectural decoration material combining light weight, high strength and excellent plasticity, has its product quality directly determined by the rigor of the production process. This article will comprehensively analyze the standardized production process and core technical key points of GRC, from material proportioning and mold making to forming and curing, providing a professional reference guide for industry peers. For more industry information: +WeChat qlfsbl123

Core Composition and Scientific Proportioning Process of GRC Materials

The performance foundation of GRC materials stems from precise raw material proportioning, and Qinglong uses a digital control system at this stage to ensure stability. The main raw materials include high-strength low-alkali cement, alkali-resistant glass fiber (usually AR glass fiber with a zirconia content ≥16%), quartz sand, water and special additives. The glass fiber content must be strictly controlled at 3%-5%, which ensures a flexural strength above 20MPa while avoiding cracking risks caused by uneven fiber distribution. Through a proportioning database accumulated over 28 years of practice, Qinglong can adjust formulas for different application scenarios (such as exterior wall cladding panels, garden sculptures and European-style moldings); for example, anti-permeability additives are added for coastal high-humidity environments to ensure the durability of GRC components.

Mold Making: The Foundation for Achieving Complex GRC Shapes

Mold technology is the key to achieving customized GRC designs, and Qinglong adopts full-process control of “3D design - CNC machining - precision verification”. For simple planar components, ABS plastic molds or fiberglass molds (GRP molds) are usually used, with a surface smoothness of up to Ra≤3.2μm; for complex shapes such as hyperbolic surfaces and openwork reliefs, 3D scanning technology is first used to establish digital models, and then high-density foam or resin molds are CNC-carved to meet the design requirement of a minimum curvature radius ≤300mm. After completion, molds must undergo a 24-hour pressure test to ensure no deformation occurs during production; this step directly affects the dimensional accuracy and surface texture of GRC products.

Forming Process: Precise Transformation from Slurry to Components

In the GRC forming stage, Qinglong mainly adopts a combination of the spray-up process and the premix casting process. The spray-up process is suitable for thin-walled components (thickness can be controlled at 10-20mm); glass fiber and cement slurry are evenly mixed through a high-pressure spray gun and sprayed onto the mold surface, with fibers distributed in a three-dimensional random orientation to enhance overall flexural performance; the premix casting process is used for components with thicker structures or heavier loads, requiring a vibrating table to remove air bubbles and ensure compactness. Notably, Qinglong introduced BIM technology in the forming process, using digital twins to simulate the stress state of components and optimize fiber arrangement direction. This technology was applied to the Dongguan Women and Children's Activity Center project, helping it win the Silver Award of the first AALBORG WHITE Cup GRC Construction Engineering Innovation Award.

Curing Process: The Core Step to Ensure GRC Strength and Durability

Curing is the final key process in GRC production. Qinglong has established a standard curing workshop, adopting a combined method of “steam curing + natural curing”. Formed components are first cured in a 60-80°C steam environment for 8 hours to accelerate cement hydration, reaching 90% of the design value in 7-day compressive strength; they are then transferred to natural curing for 21 days to ensure steady strength growth. Temperature and humidity must be monitored in real time during curing to avoid surface cracking caused by sudden temperature changes. GRC components treated by this process can withstand 300 freeze-thaw cycles without damage, fully meeting the requirements of the Technical Standard for Building Applications of Glass Fiber Reinforced Cement (GRC) (JGJ/T423-2018).

As a member of the International GRC Association and a participant in industry standard development, Qinglong always controls the entire production process with a meticulous and detail-oriented attitude. From material screening to finished product delivery, every GRC component must go through 12 quality inspection procedures to ensure that products delivered to customers combine aesthetic effects with structural safety. Whether it is the special-shaped exterior walls of commercial complexes or artistic sculptures in landscape gardens, Qinglong GRC can turn design creativity into architectural reality with its mature production processes and full-chain service capabilities. For more industry information: +WeChat qlfsbl123