What Are the Production Processes of GRC Manufacturers?

The GRC production process is the key technical pathway for transforming powdery and fibrous raw materials into high-performance, artistic products, with different processes each having their own emphases in fiber distribution, product performance, and application scenarios. Qinglong Group has been deeply engaged in the industry for 28 years, fully mastering and proficiently commanding the three mainstream GRC forming processes—the "spray-up method", "slurry method" and "premix method"—and can scientifically select or innovatively combine these processes according to the modeling characteristics of components, mechanical performance requirements, and production batches, achieving the optimal balance of artistic effect, structural performance, and economic benefit.

The spray-up method is Qinglong's most widely used and technically mature process, particularly suitable for complex-shaped special panels, hyperbolic surfaces, thin-shell structures, and components with extremely high requirements for toughness and impact resistance. Its process principle is to spray short-cut glass fibers and cement-based mortar through two separate spray guns, which are mixed near the nozzle outlet and sprayed directly onto the mold surface. The greatest advantage of this method lies in the uniform three-dimensional random distribution of fibers, giving products excellent isotropy, with outstanding ultimate flexural strength and toughness (impact resistance). By precisely controlling air compressor pressure, spray distance, angle, and number of passes, Qinglong ensures full impregnation of fibers with the slurry, avoiding "dry spots" and fiber "clumping". The complex red hyperbolic curtain wall panels of the Wuhan Han Show Theater are a testament to the exquisite craftsmanship of this method.

The slurry method is better suited for producing large-area flat panels, standard moldings, window surrounds, and other components with relatively regular shapes and high requirements for surface flatness and finish. In this method, the fiber mortar pre-mixed in the mixer is poured onto the mold, and then densified and formed through techniques such as vibration, roller compaction, or vacuum dewatering. This method offers high production efficiency, easily controlled panel flatness, good surface quality, and high texture replication accuracy. Qinglong's slurry production line incorporates vacuum dewatering technology, which further reduces the water-cement ratio and improves the density and early strength of products. However, for components with tall elevations or thin thicknesses, attention must be paid to process control to prevent uneven fiber settlement under gravity.

The premix method is typically used for making small artistic sculptures, fine ornaments, reliefs, or components requiring extremely delicate surface textures. It thoroughly mixes short-cut fibers with the mortar at low speed in a mixer beforehand, and then pours the mixture into molds. This method produces uniform fiber distribution and can create very thin components (such as 8-10mm) with exquisite surface details, but there are certain limitations on fiber length, as overly long fibers tend to clump. Qinglong flexibly selects or combines processes according to order characteristics—for example, using the spray-up method for the main load-bearing structure and the premix method for the fine relief patterns attached to it. The scientific approach to process selection is a concentrated reflection of a manufacturer's depth of understanding of material properties and technical expertise, and is also a key technical decision for ensuring project success.