Multi-Purpose GRC Production
Package Includes:
Machinery
- WAAPS 3000 – Water, Polymer and Admixture dispensing system
- GRC125 Combination Slurry/Premix GRC mixer (with bucket trolley)
- PS38A Combi Spray Station – includes Concentric Spray Head, MK5A Premix Spray Gun, articulated boom and accessories pack
- Large Vibrating Table 2.2 x 1.2 x 0.5m
- MK3 Powertex Facing Coat Spray Gun (+ airline)
Accessories
- GRC thickness measuring gauge
- Slump test kit
- ‘Wash-Out’ test baskets (x3)
Traditional Hand Spray is a time-tested method. Used for decades in GRC production, it’s the most versatile and popular production technique and the one most often chosen by new start-ups.
Through a specially designed spray gun – such as the Concentric Spray Gun – manufacturers simultaneously spray chopped AR Glass Fibres and cementitious slurry onto a mould, efficiently distributing fibre throughout the mix. This process is followed by hand compaction using a Spring Roller to ensure maximum flexural strength is achieved.
This method is known for achieving the highest strength levels, attributable to its high content of AR Glass Fibre (4-5% by weight), elongated fibre lengths and planar fibre orientation.
As the name suggests, the Spray Premix method involves the spraying of premixed GRC. Prior to spray application, chopped AR Glass Fibre and a cementitious slurry are combined before being subsequently applied using a specially designed spray gun such as the MK5A.
Compared with Traditional Hand Spray, strengths attained through the Spray Premix method are generally lower, mainly due to the reduced AR Glass Fibre content (generally around 3% by weight), shorter fibre lengths and a multi-dimensional fibre orientation.
Although falling short in this respect, the Spray Premix approach stands out by delivering mechanical properties that are more consistent and, in some cases, superior to those attained through the Cast Premix method. Moreover, this technique ensures uniform distribution of fibres throughout the mix, resulting in GRC products that exhibit exceptional integrity and strength.
By combining the advantages of both Traditional Hand Spray and Cast Premix methods, Spray Premix is fast becoming the method of choice for producing a vast variety of smaller architectural items.
Cast Premix is one of the simplest methods of producing GRC, requiring just a mixer and raw materials.
The method involves mixing chopped AR Glass Fibre into a cementitious slurry before being poured directly onto a mould. The key to getting the best results is in the speed of the mixer: running it too fast risks overmixing and adversely affecting the fibre strand integrity, whilst running it too slow risks uneven fibre distribution throughout the mix.
Once prepared, the resulting GRC mix can be poured directly onto moulds and compacted using either vibration or through admixtures included in the mix, such as Flowaid SCC.
The mix is left in the mould and cured for 24 hours underneath polythene to prevent moisture loss. After this period of curing, the product is demoulded and left to remain curing in moist conditions under polythene for a further 7 days.
Cast Premix is a favoured method for the manufacture of standardised products due to the ease of automation it offers. Even when using complex moulds, manufacturers can be assured of consistent results, although with slightly lower mechanical properties.
Other Packages Available...
The simplest method of manufacturing GRC, made even easier with Power-Sprays’ production technology
A flexible option, enabling manufacturers to produce both Traditional Hand Spray and Cast Premix GRC
Versatile, efficient, and the most popular production method chosen by new start-ups
