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GFRC facade panel design and fabrication drawings for a set of projects worldwide

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GFRC facade panel design and fabrication drawings for a set of projects worldwide

Overview

Over the years, the ORIGIN team has successfully delivered multiple modeling projects focused on the detailed design and development of GFRC facades. Each project involved the creation of complex facade panel geometries, carefully tailored to meet specific architectural intent, structural requirements, and environmental conditions.

Input: Architectural design sketches and initial conceptual models; General structural design requirements.

Output:

Detailed 3D models of GFRC panels and framing systems;
Shop drawings, manufacturing, and installation documentation;
Mold fabrication drawings.

Services:	ARCHITECTURE
Subservices:	GFRC facade panel design, Fabrication/Installation drawings
Industry:	Mixed-use
Object type:	Mixed-use
Tools used:	ARKANCE (AGACAD) Smart Documentation, Dynamo, Autodesk Revit
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Project stages

1. Analysis of architectural and structural inputs

2. GFRC panel (skin) design

3. Frame system design

4. Design of flexible attachment mechanisms

5. Final assembly

6. Development of manufacturing and installation documentation

Our approach to GFRC projects

Reliable delivery and high-quality results even on demanding timelines;
Close collaboration with clients throughout all project stages;
Detailed manufacturing documentation that ensures accuracy and supports efficient production;
Efficient application of custom tools and automation workflows to streamline processes and reduce errors.

In this case, we’ll take a deep dive into the intricacies of GFRC 3D modeling, including challenges, processes, bottlenecks, and the expected benefits.

Challenges & Solutions

One of the key GFRC project challenges lies in accommodating complex panel geometries and tight on-site tolerances. To address this, the ORIGIN team implements a variety of framing systems with a strong focus on the precision and flexibility of the attachment mechanisms, thus ensuring solid support for the GFRC panels.

Another key challenge is accommodating structural and fabrication tolerances. To address this, special attention is given to integrating custom components into the attachment system. This guarantees a reliable and consistent installation despite on-site variability.

Architectural and structural input analysis

Each GFRC project begins with a thorough review of design sketches and structural requirements. At ORIGIN, we typically work from general to specific.

Often, there is a need for large, intricately shaped panels and the integration of structural frames within tight spatial constraints. In this case, we apply detailed geometric planning, break down facades into manageable zones based on geometry and structural complexity, and coordinate closely with structural engineers to optimize frame positioning.

Components of GFRC cladding panels

As illustrated, the types of components used in the production of glass reinforced concrete cladding panels are the following:

GFRC skin. This is the exterior surface of the panel, shaped to meet design intent and built for durability.

Flexible attachment mechanism. This system connects the GFRC skin to the frame while allowing for thermal expansion and mitigating drying shrinkage or moisture-induced movements.

Steel frame. The frame provides structural support and ensures the panel remains rigid during handling and installation.

GFRC skin design

At this stage, each GFRC panel skin is tailored to meet architectural specifications while maintaining a balance of lightweight and high-strength properties. Panels feature both smooth and textured finishes.

ORIGIN experts highlight the following GFRC skin design properties that help achieve outstanding results:

Reduced joint requirements. Large-scale GFRC skins minimize the number of joints, creating a seamless and polished facade.
Support for complex geometries. Glass fiber concrete easily accommodates curved, angular, and geometrically complex forms due to its manufacturing technology.
High adaptability. The material is well-suited for custom shapes and intricate architectural details.
Design flexibility. GFRC allows architects to push the boundaries of facade design and realize bold, creative concepts.

Frame design

At this stage, ORIGIN experts develop the structural backbone of each GFRC panel. Since the frames are responsible for supporting the panel’s weight and ensuring stability under various load conditions, various frame design techniques should be used here. For example, flat rectangular frame configurations can be suitable for standard-sized panels, while irregularly shaped panels require fully customized framing solutions.

In doing so, structural engineers determine the size and type of steel elements based on load calculations. Our role at ORIGIN is to seamlessly integrate these specifications into the overall panel design. To achieve this, we carefully plan, refine, and optimize each frame layout to ensure both performance and compatibility with the GFRC.

Going the extra mile:

Additionally, even though hot-rolled steel is commonly used, we also explore lightweight steel options in cases where weight reduction or installation conditions demand alternative solutions.

Flexible attachment mechanism design

This stage focuses on developing the connection system — a critical component of every GFRC project. The connection between the GFRC skin and the supporting steel frame is achieved through a flexible attachment mechanism, designed to handle structural movement and maintain panel stability.

Due to varied attachment scenarios and space constraints, this phase requires meticulous coordination to adapt the system to project-specific conditions and guarantee long-term durability.

At ORIGIN, we ensure the system is strong enough for the panels to withstand various external forces: wind loads, seismic activity, thermal expansion, and more. Additionally, its goal is to mitigate the effects of drying shrinkage and moisture-related movement. Considering this, each component within the attachment system is purpose-built to ensure reliable performance and smooth integration with the panel and frame assembly.

Final assembly

Finally, the GFRC skin, the steel frame, and the flexible attachment mechanism come together to form a single functional system: the frame handles structural loads, and the attachment mechanism ensures secure connections that absorb stress and allow for movement.

At ORIGIN, we carefully engineer this assembly to meet both technical demands and aesthetic goals. By focusing on the role of each component and ensuring seamless coordination between them, we create GFRC facades that stand out for their strength, precision, and long-term performance.

Development of manufacturing and installation documentation

As a final touch, our team provides detailed manufacturing documentation to ensure that every design is translated into a high-quality, precisely built, and easy-to-install product. It commonly includes:

Part manufacturing drawings – our key reference for fabricating GFRC skins in the factory environment (covering panel shape, size, surface finish, alignment, tolerances, and other crucial aspects);
Frame manufacturing drawings – used for accurate frame assembly, including dimensions, flexible attachment layouts, welding instructions, vent hole locations (for HDG), connection sequences, and more;
Localized documentation in English, Spanish, or other languages upon request.

The extra mile

Upon request, we offer the following outputs to support advanced production and customization:

SAT files for seamless 3D modeling and CNC machining;
Unfolded views for bent steel fabrication;
Comprehensive steel detailing documentation;
Clear installation drawings for on-site teams;
Optimized packaging plans for sea transportation.

Custom Tools and Automation

At ORIGIN, we develop proprietary tools and scripts that integrate seamlessly with ARKANCE (AGA CAD) Smart Documentation, Dynamo, and other add-ons to streamline the creation of manufacturing documentation.

These tools automate repetitive tasks, enable parameter-driven adjustments, and ensure a logical sequencing of views. By leveraging these innovations, we reduce manual errors, enhance accuracy, and boost overall project efficiency.

Our team has extensive experience in producing precise drawings and is constantly refining our processes. We create custom tools to deliver innovative and efficient solutions tailored to the unique demands of each project.

Gallery

GFRC Panels Examples