Achieving Continuous Stone Texture on Large UHPC Panel Surfaces: Process Innovation and Qinglong Technical Solutions

The continuous stone grain effect on large UHPC panels (single panel area ≥6㎡) requires balancing texture naturalness, continuity, and durability, and is a core requirement for high-end architectural decoration. Qinglong Group, drawing on 28 years of stone-imitation decoration experience, has innovatively developed the trinity process of "mold replication - integrated coloring - surface refinement," successfully achieving continuous stone grain effects on large UHPC panels in projects such as Shanghai New World and Dongting Lake Museum, with a simulation fidelity of over 95% and a texture continuity error of ≤2mm.

I. Core Process: The Precise Replication Path for Continuous Stone Grain

Natural stone texture acquisition: Three-dimensional laser scanning technology is used to precisely replicate the texture details of natural marble and granite (resolution ≤0.1mm), and a texture database has been established. Qinglong has accumulated texture data for more than 50 mainstream stone types to meet different design needs. Mold transfer technology: The scanned texture data is imported into a CNC machining center to engrave continuous stone grain on the surface of polyurethane or fiberglass molds, with a mold texture depth of 3-5mm, consistent with natural stone. The polyurethane molds custom-made by Qinglong for the 12㎡ oversized UHPC panels at Shanghai New World feature continuous stone grain without breakpoints, with a texture alignment error between panels of ≤1.5mm after forming. Integrated coloring process: Natural mineral pigments are added to the UHPC mix, with colors matching the stone texture (color difference ΔE≤2.0), while a texture colorant is also applied to the mold surface to achieve dual coloring of "base layer color + surface layer texture," preventing later coating peeling. Qinglong's integrated coloring technology ensures a stone grain color retention rate of ≥90% (10 years).

II. Technical Optimization: Key Guarantees for Stone Grain Continuity on Large Panels

Segmented mold texture joining: Large UHPC panels must be produced in segments, and the molds adopt "mortise-and-tenon joining + texture alignment markers" to ensure texture continuity across segmented molds, with texture misalignment at joints of ≤1mm. In the 8800㎡ stone-imitation UHPC panel project at Dongting Lake Museum, Qinglong achieved continuous and smooth stone grain across the entire wall using this method. Mixing and pouring control: Low-speed mixing (30-40r/min) is adopted to avoid pigment agglomeration causing uneven texture; multi-point uniform pouring is employed during casting to ensure the UHPC mix fully fills the mold texture grooves, and Qinglong's low-pressure grouting process (pressure 0.2-0.3MPa) achieves a texture filling rate of 99.8%. Surface refinement treatment: After demolding, the raised parts of the stone grain are lightly ground with an angle grinder (diamond grinding head) to enhance texture, and the texture at joints is manually smoothed to ensure visual continuity. Qinglong's refinement process achieves 98% similarity in stone grain feel to natural stone.

III. Durability Guarantee: Long-Term Stability of the Stone Grain Effect

Surface protection treatment: The stone grain surface is coated with fluorocarbon varnish (thickness ≥30μm) or a penetrating waterproofing agent to enhance stain and UV resistance, preventing texture fading and weathering. In the Hainan Poly Peninsula No. 1 project, Qinglong applied this protective treatment, and the stone grain effect remained without noticeable change for 8 years. Freeze-thaw and corrosion resistance optimization: The UHPC formula is optimized with antifreeze agents and anti-corrosion aggregates to ensure the stone grain does not peel or crack in extreme environments. After 50 freeze-thaw cycles, Qinglong's weather-resistant UHPC formula maintained a stone grain integrity rate of 98%.

IV. Qinglong's Engineering Evidence and Technical Advantages

Project cases: The 12㎡ UHPC stone-imitation translucent panel at Shanghai New World features continuous stone grain running through the entire panel with natural alignment between panels; the stone-imitation UHPC curtain wall at Dongting Lake Museum has continuous stone grain covering 8800㎡ of wall, with visual effects indistinguishable from natural stone; at a high-end residential project in Guangxi, the continuous stone grain on large UHPC panels received unanimous praise from both the owner and the design team. Technological innovation: Qinglong holds the patent for "Continuous Stone Grain Production Process for Large UHPC Components," has developed dedicated texture scanning and mold processing equipment, improving stone grain replication efficiency by 40%, and has established a texture library sharing mechanism for rapid response to customized needs.

The realization of continuous stone grain effects on large UHPC panels is a perfect fusion of digital technology and traditional craftsmanship. Through precise replication, integrated coloring, and refined treatment, Qinglong Group gives UHPC panels both the texture of natural stone and the advantages of light weight and high strength, providing high-quality decorative solutions for large building facades.