Yesterday we had the wonderful opportunity to visit the manufacturing plant of
E-Grow, a maker of advanced materials for building cladding using fiber reinforced polymers and fiber reinforced gypsum. The founder, who is trained as an architect, gave us a presentation on the buildings in which his products have been installed.

This is the reception and meeting area.

This light fixture was designed by Zaha Hadid. We saw a presentation on their work for the new Guangzhou Opera House by Zaha, for which they clad the entire 5,500 square meter interior with custom panels of glass reinforced gypsum over the walls and ceiling. Here are pictures of the finished project from the manufacturer's
website. The project is also discussed in
ArchDaily.

Celebrating at the opening party:

For this project the factory operated three shifts 24 hours a day, running twelve CNC machines that created fifty panels a day. Because of the sinuous shape of the design, no two panels are alike. The project was completed and installed in five months.

E-Grow uses an innovative and patented method of casting molds of wax. For the Guangzhou project they created three custom molds per day. Here are pictures of the machines creating custom molds in which casts will later be made.

The residue of the mold-making process is wax, which is environmentally safe. It can be reused in new molds, so there is virtually no waste in the process.

A finished glass fiber reinforced plaster panel from a new project in construction.

The owner showed us the process of casting with fiber and gypsum plaster. We were also introduced to the use of the company's products in exterior cladding, such as for Thom Mayne of Morphosis' project of the Giant Interactive Group campus in Shanghai. It is located in Songjiang, in the same area the plant is located. There is an interesting description about the creation of this new campus in this
article. Here are some pictures from that article.

The company created the custom rounded columns seen in these pictures, taken by photographer Iwan Baan.

The conference room in the executive suite has a glass floor. That is unusual, but I digress.

For the MOCA installation in Shanghai, E-Grow has cleated these leaf-like metal ceiling panels.

In Wuxi, the company is creating interior cladding for the Lingshan Buddhist Scenic spot. The design institute ECADI is the architect.

For transportation, the panels are divided into four pieces and assembled in site. Here are some pictures of the finished ceiling from E-Grow's website:

Next we toured the control room of the CNC machines and the design studio.

The company has a plant for manufacturing of metal panels used in interior and exterior applications. For the United Arab Emirates pavilion of Expo designed by architect Norm Foster, E-Grow shaped the Rimex roof panels. Here is a picture of the installation:

Samples of metals used and a panel in construction:

A worker finishing parts for a glass railing for an airport metro stop.