Fiber cement production

Fiber cement combines malleability during production with exceptional strength once cured. Its durability is the result of a precisely engineered material composition, continuously refined through research and innovation.

Backed by decades of manufacturing expertise, skilled craftspeople produce Swisspearl panels with precision and care. This balance of tradition and innovation has supported architectural projects around the world for more than 100 years.

The core components of Swisspearl fiber cement include cement, fillers, cellulose, synthetic fibers, color pigments, and water. Depending on the application, additional functional materials may be incorporated. Health and environmental safety are central to Swisspearl’s research and development process, guiding both material formulation and raw material selection.

While all nine Swisspearl production facilities have been completely asbestos-free for more than two decades, asbestos was historically used across the fiber cement industry for its durability and strength. When studies confirmed the health risks associated with asbestos, Swisspearl launched an extensive research and development program to eliminate it from its formulations.

Swisspearl was among the early leaders in this transition, beginning the phase-out in the 1980s, well before stricter European regulations on asbestos came into effect.

Cellulose bales are first dispersed in water and refined to the required fineness. The processed cellulose is then fed into a mixer along with cement and the remaining raw materials, where continuous agitation creates a uniform slurry.

Because cement bonding reactions begin immediately when combined with water, the slurry is transferred without delay to the production line for further processing.

In the production line, the slurry is pumped into basins equipped with rotating cylindrical screens. The plate maker, based on the Hatschek process, typically uses three to four rotating screens to gradually build up the panel layers.

On the surface of each rotating screen, suction inside the drum forms a thin layer of slurry, approximately 0.04 inches thick. These fiber cement layers are transferred from the screens onto a rotating felt, where they are built up layer by layer.

The multilayer sheet is then wrapped around a format roller until the required panel thickness is achieved.

This process takes approximately 20 to 100 seconds, depending on panel size and format. The diameter of the format roller defines the panel length, which is cut to its raw format using a corresponding blade. Producing a different format requires retooling these units.

At this stage, the fiber cement still contains a high level of moisture, and the curing process is actively underway.

In addition to Hatschek technology, Swisspearl also uses flow-on technology. In this process, a thin fiber cement layer is applied directly onto a felt from a head box. The single layer is then wrapped around the format roller, similar to the Hatschek process.

First, the panels are stacked between steel sheets and pressed under pressures of up to 10,000 tons to remove excess water. This step reduces moisture content from approximately 28 percent to about 15 percent while increasing panel density. The remaining water continues to react with the cement as hardening progresses. This process releases heat and takes place in a dedicated curing hall. 

After several weeks of curing, moisture content is typically reduced to 7 to 8 percent. Curing time can be significantly shortened through autoclaving, where panels are steam cured under high temperature and pressure.

Depending on the required performance characteristics, some panels undergo additional processing. This may include further drying in a furnace to precisely control moisture levels and fine-tune durability properties.

Swisspearl offers a broad color range that meets most design requirements. Panels can be colored-through by adjusting the slurry during production. Surface colors are poured or sprayed onto the panels to achieve the desired finish, and nearly any surface color can be applied on request.

Color options range from opaque to translucent, allowing subtle interaction between surface texture and color. In addition to color, surface treatments play a key role in the overall appearance of the facade. These treatments create distinct visual effects, with each color line carefully coordinated to ensure a consistent and refined architectural result.

Swisspearl fiber cement supports a wide range of surface finishes, including sanded, milled, iridescent, and natural smooth. Ongoing research and development continue to expand these options with specialized finishes.

Product families are developed for specific applications, with standard panel formats aligned accordingly. Flat panels are available in thicknesses ranging from 0.13 to 0.47 in (3–12 mm), depending on the product line. In addition to formats optimized for direct installation, many products are available in a maximum standard size of 120.08 × 49.21 in (3050 × 1250 mm) for custom fabrication.

Special production is also available on request, including custom cutting, milling, perforations, and decorative detailing.