UHPC Curtain Wall Panel Factory Prefabrication: Qinglong Reveals Six Key Steps

Factory prefabrication is the core process for ensuring the quality of UHPC curtain wall panels, and a standardized, refined production flow directly determines the precision and performance of components. As a company with a large production base in Nanning, Guangxi, Qinglong Group draws on 28 years of prefabrication experience to break down the key steps of UHPC curtain wall panel factory prefabrication, revealing the core logic of industrialized production.

I. Step 1: Raw Material Inspection and Mix Ratio Optimization ✅

Before prefabrication, UHPC core raw materials must undergo strict testing: cement strength grade ≥52.5MPa, quartz sand particle size controlled at 0.15-2.36mm, and steel fiber length of 12-18mm with a diameter of 0.2-0.3mm. Qinglong has established a three-level inspection system with a 100% raw material pass rate. The mix ratio is optimized according to project requirements—for example, increasing the fine aggregate proportion for openwork panels and adjusting admixture dosage for double-curved panels—to ensure the concrete meets workability and strength requirements.

II. Step 2: Mold Fabrication and Installation Positioning

Molds are fabricated according to design drawings: standard components use GRP molds, while complex shapes use steel or polyurethane molds. Mold installation must ensure a flatness error ≤2mm/m and a dimensional deviation ≤3mm. For the Shanghai New World project, Qinglong used 3D scanning and modeling for the wood-effect translucent panel molds, ensuring a texture fidelity of 98%. After installation, molds are cleaned and coated with release agent; a water-based release agent is applied uniformly at a thickness ≤0.1mm.

III. Step 3: Rebar Processing and Placement

Rebar is mechanically cut and bent with a dimensional deviation ≤5mm, then rust-treated and placed according to the drawings. The protective cover thickness is controlled at 15-20mm and secured with special spacers to ensure accurate rebar positioning. For the UHPC curtain wall panels of the Yangshengtang Pharmaceutical Hangzhou Industrial Park, Qinglong configured a double-layer rebar mesh fixed by spot welding to prevent displacement during pouring.

IV. Step 4: Mixing, Pouring, and Vibration Compaction ⚡

Vacuum mixing equipment is used with a mixing time ≥5 minutes to ensure uniform material blending and an air bubble content ≤1%. Pouring adopts layered placement with each layer thickness ≤50mm and a pouring speed controlled at 0.5-1m³/h. High-frequency vibrating tables (frequency 50-60Hz) are used for vibration compaction to ensure concrete density, supplemented by internal vibrators for large components. In the Huawei Bantian Headquarters project in Shenzhen, Qinglong adopted an automated pouring line, improving pouring precision by 30%.

V. Step 5: Steam Curing and Natural Curing

Steam curing begins within 2 hours after pouring, with the temperature gradient controlled at 10℃/h, a maximum temperature of 90℃, and a curing time ≥24 hours. After curing, panels are transferred to natural curing for ≥7 days, with ambient humidity maintained at ≥90%. Through an intelligent curing system, Qinglong monitors temperature and humidity in real time to ensure UHPC meets strength requirements (compressive strength ≥150MPa).

VI. Step 6: Demolding Inspection and Surface Treatment

Demolding is permitted only when strength reaches more than 75% of the design value. After demolding, appearance inspection and dimensional verification are carried out, with a surface defect rate ≤1% and dimensional deviation ≤3mm. Surfaces must be ground and polished, with a flatness error ≤2mm/m. Qinglong has established a traceability mechanism for non-conforming components with timely rectification, achieving a 100% factory pass rate.

Factory prefabrication of UHPC curtain wall panels is a comprehensive reflection of technology, equipment, and management. With an annual production capacity of 600,000 square meters and a standardized production system, Qinglong ensures consistent quality in every component. From raw materials to finished products leaving the factory, six key steps provide layer-by-layer control, delivering high-precision, high-performance UHPC curtain wall panel products for projects.