Analysis and Optimization of Key Production Process Points for High-Strength GRC Panels

In the field of architectural decoration materials, GRC has become an ideal choice for modern building envelope design thanks to its lightweight, high strength, and rich formability. As an industry practitioner with 28 years of full-chain experience in UHPC/GRC/GRG/GRP materials, Qinglong Group has always believed that the quality breakthrough of high-strength GRC panels depends not only on optimizing material formulations, but also on systematic control of production processes. This article provides an in-depth analysis of the key points in high-strength GRC panel production—from material proportioning and forming processes to quality inspection—and, drawing on the technical expertise of Qinglong's national-level R&D center, explores paths for process optimization.

1. Composite Raw Material Proportioning: The Foundation of High-Strength GRC Panel Performance

The core advantage of high-strength GRC panels lies in the balance between "lightweight" and "high strength," and achieving this balance starts with the scientific proportioning of raw materials. In production, Qinglong strictly complies with the Technical Standard for Building Applications of Glass Fiber Reinforced Cement (GRC) (JGJ/T 423-2018), carefully selecting high-grade sulfoaluminate cement, alkali-resistant glass fiber (content ≥5%), quartz sand, and functional additives to form a three-dimensional "cement–fiber–aggregate" reinforcement system. The length of the alkali-resistant glass fiber is controlled at 12-25mm to ensure uniform fiber dispersion in the matrix, achieving flexural strength of over 20MPa—a 30% improvement over traditional GRC. In addition, by incorporating nano-grade silica fume and compound water reducers, the water-cement ratio is effectively reduced to below 0.35, enhancing the panel's density and impermeability. This proportioning scheme has passed the Guangdong Provincial Science and Technology Achievement Appraisal and has been applied to benchmark projects such as the Dongguan Women and Children's Activity Center.

2. Forming Process Innovation: A Breakthrough from "Standardization" to "Customization"

The forming process of high-strength GRC panels directly determines their mechanical performance and surface precision. Qinglong adopts a "spraying–premix composite process," combining automated production lines with 3D CNC molds to ensure both complex shapes and structural strength. During the spraying stage, fiber and cement mortar are evenly mixed through high-pressure spray guns, ensuring random fiber orientation; the premix process, designed for large flat panel components, uses mechanical mixing and vacuum degassing technology to reduce internal air pockets. Notably, for special-shaped components such as double-curved and hollow-out panels, Qinglong introduces BIM technology and Rhino parametric design, together with adjustable flexible molds, keeping the minimum curvature radius within 300mm to meet the customization needs of high-end scenarios such as the translucent concrete project at Century Plaza on Nanjing East Road. In addition, the steam curing stage follows a "gradient heating" regime (20℃→60℃→80℃) to prevent micro-cracks caused by thermal stress, with the 28-day compressive strength of cured panels stably exceeding 60MPa.

3. Quality Inspection and Full-Process Control: Building a Solid Safety Line

As a national "Specialized, Refined, Distinctive, and Innovative" enterprise, Qinglong has established a full-process quality control system covering "raw materials–production–shipment." Each batch of glass fiber must pass alkali-resistance testing (strength retention rate ≥75% after 28 days of immersion), and radioactivity testing of cement and aggregates complies with the GB 6566 standard. During production, RFID chip implantation technology records the production time, curing parameters, and inspection data of each component, enabling traceable management. Before shipment, sampling tests are conducted in accordance with Glass Fiber Reinforced Cement (GRC) Decorative Products (JC/T 940-2022), focusing on verifying key indicators such as flexural strength, elastic modulus, and frost resistance (no damage after 25 cycles between -20℃ and 20℃). For overseas projects (such as Malaysia and Saudi Arabia), products must additionally pass the ASTM C1185 impact resistance test to ensure adaptation to different climatic environments.

4. Process Optimization Directions: Green and Intelligent Upgrading

In line with industry development trends, Qinglong is advancing process optimization for high-strength GRC panels in two areas: first, green production—replacing 30% of aggregates with industrial solid waste (such as fly ash and slag) to reduce carbon emissions, a technology that has earned multiple invention patents; second, intelligent upgrading—introducing an AI visual inspection system that identifies surface defects (such as bubbles and cracks) in real time, with detection accuracy of 0.1mm and a 25% increase in production efficiency. Looking ahead, as the industry standard General Technical Conditions for Non-Load-Bearing Components of Ultra-High Performance Concrete (UHPC) advances, Qinglong will further explore the composite application of GRC and UHPC, developing a new generation of decorative components with higher strength and lighter weight.

From material R&D to engineering implementation, the production process of high-strength GRC panels is the crystallization of technology and experience. Building on 28 years of industry expertise, Qinglong Group—through its process system of "scientific proportioning, refined forming, and rigorous inspection"—provides designers and owners with solutions that combine aesthetic value with structural safety. Driven by its mission to "create beautiful architecture," Qinglong will continue to promote technological innovation in GRC materials, helping more landmark buildings achieve a perfect fusion of art and engineering.