Project Case: School Facade Retrofit in Spain

Project Profile

• Location: Spain
• Application Area: School Teaching Building Facade
• Project Area: 95,000 ㎡
• Product: Split Face Brick Texture Flexible Stone
• Core Challenges:
  1. The originally designed split face tiles were too small (60*240mm), resulting in extremely high local labor costs that exceeded the budget, and the massive number of joints made construction highly difficult.
  2. Extremely short construction period: The school facade retrofit could only be carried out during the summer vacation and had to be completed before the new semester started.
• Our Countermeasure: Re-developed custom molds to produce 600*1200mm ultra-large format split face tiles, with pre-grouting completed at the factory. On-site, they are directly thin-bed applied, drastically reducing on-site labor and completely solving the schedule and budget challenges.

Background & Challenges

This school is located in Spain. To enhance the campus image and solve the aging exterior wall problem, it was decided to conduct a comprehensive facade renovation. The design selected a split face brick texture with a strong traditional European architectural style (as shown in the image).

However, this mega-project of 95,000 square meters encountered an almost unsolvable dilemma during implementation:

1. The “Assassin” of European Labor Costs: Traditional split face tiles are only 60*240mm, requiring nearly 70 pieces to cover one square meter. In Spain, where labor costs are extremely high, the on-site tiling and grouting costs alone would bankrupt the project budget. Meanwhile, construction speed was extremely slow, making quality control difficult.
2. The “Extreme Schedule” of Summer Vacation: School projects have strict physical deadlines—they must be delivered before school starts in September. Traditional laying processes could not complete such a massive workload within the stipulated time.

The Solution: Large Format Customization + Factory Pre-Grouting

Facing the dual extreme pressure of budget and schedule, the technical team at Guangdong Fortune Stone New Material Co., Ltd. proposed a subversive “dimensional reduction” solution:

1. 600*1200mm Ultra-Large Format Mold Development: We re-developed custom molds for this project, transforming the originally fragmented small bricks directly into 600*1200mm large panels. Less than 2 panels are needed per square meter, resulting in a geometric increase in construction efficiency and directly slashing massive on-site labor costs.
2. Factory Pre-Grouting (Core Black Technology): The most time-consuming part of traditional tiling is “grouting”. During the factory production stage, we used high-precision equipment to pre-fabricate realistic recessed brick joints directly onto the large Flexible Stone panels. On-site, workers simply apply the large panels directly to the wall without needing to fill or grout, perfectly presenting the 3D texture of real brickwork.
3. Perfect Alignment with Original Architecture: The final completed red brick facade (as shown in the image) visually perfectly restores the texture and color of traditional split face bricks. It not only lacks the roughness of seams but appears even more regular and grand.

Why Flexible Stone? Four Hardcore Data Points

• ✓ Ultra-Lightweight: Areal density of just 3.96kg/㎡. For old school buildings, the large Flexible Stone panels do not add structural load to the exterior walls, avoiding expensive structural reinforcement of the original walls.
• ✓ SGS Class A2 Fireproof: Achieves the SGS certified A2-s1, d0 non-combustible standard. As schools are special places with high population density, fire safety is an absolute red line.
• ✓ Extreme Flexibility: Perfectly passes the 200mm diameter cylinder bending test. It excellently adapts to minor deformations of the teaching building’s exterior walls, and during large-area construction, it is more resistant to impact and shattering than traditional rigid ceramic tiles.
• ✓ Highly Durable: Boasts 1500-hour artificial weathering resistance. Whether facing intense Spanish sunlight or sea breezes, it maintains vibrant red brick colors for the long term without fading or efflorescence.

Project Outcome

The project was successfully completed during the summer vacation as scheduled and successfully kept the total cost within the client’s budget.

The project contractor exclaimed during acceptance: “This is simply a miracle! If we had used traditional 60240mm small bricks, it would have been impossible to finish 95,000 square meters in this summer vacation. Fortune Stone’s large format pre-grouted solution not only saved us massive labor costs but also the final red brick texture presented is very natural. This has given our school a completely new look for the new semester.”*

Related Keywords: #SpainSchoolRetrofit #SplitFaceBrickFlexibleStone #PreGroutingTechnology #EuropeanRetrofitProject #FlexibleStoneManufacturer #SplitFaceBrick #FacadeRetrofit #LargeFormatTile #GuangdongFortuneStone

📞 Large-Scale Flexible Stone Project Procurement Contact & Credentials

We are fully authorized for global export and ready to support your large-scale projects.

• Primary Contact: LILY LIU (Legal Representative & General Manager of Overseas Export Dept.)
• Mobile / WhatsApp: +86 15766615138
• Address: Luoyang Street, Boluo County, Huizhou City, Guangdong Province, China.

Verified Company Credentials:

• Company Name: Guangdong Fortune Stone New Material Co., Ltd.
• Unified Social Credit Code (USCC): 91441302MA52XYL39Q
• Established: 2019 (Legally registered and compliant operation)
• Import/Export License: Fully authorized by the Chinese government for “Cargo Import & Export” and “Technology Import & Export,” supporting seamless global shipping and customs clearance.

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