What Are the Key Technologies for Achieving a High Perforation Rate in UHPC Forms? Qinglong's Core Processes and Project Breakthroughs

The core of achieving a high hollow-out ratio (≥50%) in UHPC shapes lies in balancing structural stability with creative design, with key technologies concentrated in four dimensions: structural optimization, mold design, fiber distribution, and forming processes. Leveraging 28 years of process R&D and project practice, Qinglong Group has overcome the technical challenges of high hollow-out ratios, achieving stable mass production with hollow-out ratios of up to 60%. In projects such as the Ouargla Hotel in Algeria and Shanghai New World, it has created high hollow-out UHPC shapes that combine artistic appeal with structural safety.

1. Structural Optimization Technology: Strength Assurance Under High Hollow-Out Ratios

Skeletal structure design: Hollow-out patterns are optimized through parametric modeling (Rhino + Grasshopper), retaining the core load-bearing skeleton (width ≥50mm) to avoid stress concentration caused by hollowing. For the hollow-out panels of the Ouargla Hotel in Algeria (55% hollow-out ratio), Qinglong adopted a grid-like skeleton design, and the compressive strength still reaches 150MPa. Stress simulation analysis: Finite element analysis software (ANSYS) is used to simulate the stress conditions of high hollow-out UHPC, optimizing the position and size of hollowed areas and avoiding weak points. For Qinglong's Shanghai New World wood-effect light-transmitting panels (50% hollow-out ratio), the hollow-out distribution was adjusted through simulation analysis, achieving a flexural strength of ≥32MPa. Stiffening ribs: Hidden stiffening ribs (thickness ≥10mm) are set at the edges and corners of hollowed areas to enhance local strength. Qinglong's stiffening ribs are integrally formed with the main body, with no visible seams and no impact on aesthetics.

2. Mold Design Technology: Precise Replication of Hollow-Out Shapes

High-precision mold making: Polyurethane soft molds or steel molds are used, combined with 3D scanning + CNC engraving technology to precisely replicate hollow-out patterns, with mold precision ≤±0.5mm. Qinglong's high hollow-out molds use polyurethane soft molds with a texture fidelity of ≥95% and can be reused ≥50 times. Demolding design: High hollow-out molds are prone to sticking, so segmented molds + optimized release agents (special silicone-based release agents) are used to ensure smooth demolding without damaging the hollowed edges. The assembly error of Qinglong's segmented molds is ≤±0.3mm, and after demolding, the hollowed edges are smooth with no chipping. Venting and grouting channel design: The molds reserve sufficient vent holes (spacing ≤100mm) and grouting channels to prevent bubbles and voids in hollowed areas. Qinglong's grouting channels adopt multi-point uniform grouting to ensure the UHPC mix fully fills the mold, achieving a compactness of 99%.

3. Fiber Distribution Technology: Uniform Dispersion for Enhanced Integrity

Fiber selection and dosage: 12-15mm stainless steel fibers are selected at a volume dosage of 2.5%-3% to ensure fibers are evenly distributed in hollowed areas, enhancing tensile and crack resistance. Qinglong's fibers undergo dispersion treatment, achieving a distribution uniformity of 98% with no agglomeration. Mixing process optimization: A dual-shaft forced mixer is used with the mixing time extended to 4-5 minutes, combined with a vibrating distributing machine, to ensure fibers are evenly dispersed in the UHPC matrix, forming effective reinforcement especially at the hollowed skeleton areas. Qinglong's mixing process keeps the fiber distribution deviation in hollowed areas ≤5%.

4. Forming and Curing Technology: Ensuring Shape Precision and Strength

High-pressure grouting forming: A 0.2-0.3MPa high-pressure grouting process is adopted to ensure the UHPC mix (flow spread ≥750mm) fully fills the fine details of the hollow-out molds. Qinglong's high-pressure grouting achieves a compactness of 99.5% in hollowed areas with no porosity. Intelligent steam curing: The curing kiln temperature is controlled at 50-60℃ with humidity ≥90% for 12-16 hours, ensuring rapid early strength development of high hollow-out UHPC and preventing cracking caused by improper curing. Qinglong's intelligent curing enables high hollow-out UHPC to reach 80% of its design strength at 7 days. Surface finishing: Diamond polishing tools are used to treat the hollowed edges, removing burrs and flash to ensure smooth, flat edges. Qinglong's high hollow-out UHPC has an edge flatness of ≤0.3mm/m with a refined appearance.

5. Qinglong's High Hollow-Out Ratio Project Evidence and Technical Breakthroughs

Ouargla Hotel in Algeria: 50mm-thick UHPC hollow-out panels with a 55% hollow-out ratio and a grid-like skeleton design. They passed wind pressure and strength tests, fully meeting the requirements for exterior wall use, and received high recognition from the client. Shanghai New World Century Plaza on Nanjing East Road: UHPC wood-effect light-transmitting panels with a 50% hollow-out ratio, embedded with light guide rods to achieve an artistic light-transmitting effect. The largest panel measures 12㎡ and weighs over 700kg, remaining structurally stable despite the high hollow-out ratio, setting an industry benchmark. Technical breakthroughs: The hollow-out ratio reaches up to 60%, far exceeding the industry average (30%-40%); mass production of extra-large high hollow-out panels (6m×3m) has been achieved; the core processes have obtained 3 invention patents, and Qinglong participated in formulating the hollow-out-related standards in the “General Technical Conditions for Non-Load-Bearing Components of Ultra-High Performance Concrete (UHPC)”.

The key to achieving a high hollow-out ratio in UHPC shapes lies in the coordinated optimization of four major technologies: structure, molds, fibers, and forming. With parametric design, high-precision molds, uniform fiber distribution, high-pressure grouting, and intelligent curing, Qinglong Group has overcome the technical challenges of high hollow-out ratios, achieving a perfect unity of artistic creativity and structural safety. Choosing a manufacturer with high hollow-out technical capabilities and project experience is the core to the successful implementation of high hollow-out UHPC shapes.