What Are the Steps in the Production Process of UHPC Exterior Wall Decorative Lines?

UHPC exterior wall decorative lines, with their advantages of high strength, high durability, and flexible styling, have become the preferred elements for high-end building facades. Their manufacturing involves multiple precision procedures, and full-process control from design to installation directly determines the final result. As an enterprise with 28 years of experience in decorative component production, Qinglong Group draws on project practice such as the Nanning Liyuan Hotel and Guangzhou Xinghewan to explain in detail the core manufacturing processes of UHPC exterior wall decorative lines.

Detailed Design and Mold Making: The Foundation for Precise Realization of Shapes. The first step is detailed design. Based on the construction drawings, BIM technology is used to optimize the cross-sectional dimensions, connection joints, and installation methods of the lines, ensuring coordination with the building as a whole while taking into account the molding characteristics of UHPC to avoid sharp angles and overly thin sections (minimum thickness ≥15mm). Qinglong's design team generates 3D models and mold machining drawings, and mold making begins after confirmation by the client and the designers. Molds are selected as GRP molds or steel molds (GRP molds for complex shapes, steel molds for mass-produced standardized lines), machined with five-axis engraving machines to ensure mold precision ≤±1mm and surface smoothness ≤3μm. In the colored openwork decorative lines project at the Nanning Liyuan Hotel, mold engraving precision reached ±0.5mm, perfectly reproducing the carved details of the design. After the molds are completed, trial assembly and grinding are required to prevent joint misalignment in the molded lines.

Raw Material Preparation and Precise Proportioning: The Core of Performance Assurance. The raw materials are high-grade cement (P·O 52.5R), imported silica fume (purity ≥95%), high-hardness quartz sand (particle size 0.15-5mm), copper-plated steel fibers (diameter 0.1-0.2mm, length 6-12mm), and polycarboxylate superplasticizer. Qinglong precisely controls the mix proportions through an automated batching system: cementitious material content of 800-900kg/m³, water-binder ratio of 0.18-0.20, fiber content of 3%-4% (by volume), with batching error ≤±1%. The raw materials are mixed in a twin-shaft compulsory mixer for at least 3 minutes to ensure uniform fiber dispersion without agglomeration. In the European-style decorative lines project at Guangzhou Xinghewan, the precise proportioning kept the compressive strength of the lines stable above 150MPa, meeting the wind load resistance requirements of the exterior wall.

Casting, Forming, and Vibratory Compaction: Surface Texture and Densification Control. The uniformly mixed UHPC slurry is poured into the molds and compacted with immersion vibrators (30mm diameter) or vibrating tables for 10-15 seconds per point, ensuring that the slurry fills the mold corners and air bubbles are released. For complex shapes or openwork lines, vacuum-assisted molding technology is used to extract the internal air, achieving a component compactness of ≥99%. After casting, the mold surface is covered with plastic film to prevent moisture evaporation. In the decorative lines project at Zhongshan Yajule Fandeng, Qinglong's precise vibration and vacuum-assisted molding produced line surfaces free of bubbles and pitting, with smoothness reaching mirror grade (surface roughness Ra≤0.8μm), requiring no later grinding or finishing.

Curing, Hardening, Demolding, and Trimming: Performance Stability and Precision Optimization. 2-4 hours after casting (after initial setting), the components are sent into a steam curing kiln controlled at 40-60℃ with humidity ≥95% and cured for 24-48 hours, allowing component strength to reach more than 70% of the design strength. After demolding, the lines are trimmed to remove flash and burrs, and the joint surfaces are ground with angle grinders to ensure installation precision ≤±2mm. After trimming, 7 days of natural curing allow the performance to stabilize. Qinglong's curing kilns use intelligent temperature control systems with a temperature error ≤±2℃. In the European-style lines project at Nanning Nanhu Mingdu in Guangxi, the cured lines achieved a flexural strength of 28MPa with no shrinkage cracks.

Installation, Adjustment, and Finished Product Protection: Final Results and Long-Term Stability. Before installation, the substrate is cleaned and positioned with chalk lines according to the design; the lines are fixed by dry-hanging or bonding, with stainless steel connectors selected to prevent corrosion. During installation, the segments are joined one by one, verticality and flatness are adjusted, and the joints are filled with elastic sealant to prevent rainwater penetration. After installation, protective film is applied until project completion to prevent construction contamination or damage from impact. In the GRC/UHPC combined lines project at Shanghai Xinghewan, Qinglong used 3D laser scanning for positioning and installation, achieving joint precision ≤±1mm and excellent overall straightness of the lines, earning high recognition from the client.

The manufacturing of UHPC exterior wall decorative lines is a matter of precise control of the entire process of design, materials, production, and installation. Through standardized processes and refined operations, Qinglong Group ensures that every procedure meets quality requirements. When choosing a UHPC decorative line supplier, clients are advised to first examine the manufacturer's mold machining capability, automation level, and installation experience, so as to avoid insufficient line precision or substandard performance caused by rough workmanship, which would compromise the overall effect and long-term stability of the building facade.