What Are the Construction Challenges of "Zaha-Style" GRC Shapes?

“Zaha-style” GRC forms are renowned for their unique architectural language of streamlined, dynamic, multi-curved composite surfaces, and their construction process is an ultimate test of a manufacturer's coordinated capabilities in detailed design, production, and on-site installation. When tackling such highly challenging projects, Qinglong Group has summarized the core construction difficulties in four major areas: “precise shape control, support system design, spatial positioning and installation, and joint treatment.”

Precise shape control is the primary difficulty. Zaha-style forms are mostly continuous, smooth, non-repeating double-curved surfaces, placing extremely high demands on the geometric accuracy of GRC components. Any tiny production error or deformation may result in panels that cannot be joined on site or in discordant broken lines. The difficulties lie in: 1) Mould making: high-precision five-axis CNC machining is required to ensure the accuracy of the mould surfaces. 2) Production deformation control: drying shrinkage and creep of GRC during curing can cause component deformation, which must be suppressed through scientific curing regimes and springback control techniques. 3) Transport protection: irregularly shaped components are vulnerable in transit and require specially designed supports.

The design and installation of the complex support keel system is another major difficulty. To support these irregular curved GRC panels, the steel keel system behind them is often itself a three-dimensional spatial curve, and its setting-out, fabrication, and installation accuracy directly determine the overall effect after the panels are hung. Surveyors must use total stations for precise three-dimensional coordinate positioning, and welders must complete complex spatial curve welding at height, demanding extremely high technical skill. The support system must also account for the thermal deformation of components and incorporate well-designed connection nodes.

Precise positioning and installation at height is the challenge of on-site implementation. Each irregular GRC panel is unique, and its installation position and angle must be accurately located in three-dimensional space. The surveying workload is heavy and requires repeated verification. During installation, experienced workers must fine-tune bit by bit, based on survey data and using hanger systems with three-dimensional adjustment capability, until the panel edges align and the panel surfaces transition smoothly. Meanwhile, irregular panels are typically heavy and irregularly shaped, making lifting and temporary fixing difficult and carrying high safety risks. For continuous flowing curved surfaces, joint width control and sealant application also severely test the construction team's precision.